L1024 24-Ppm Continuous-Form Laser Printer

R
Maintenance Manual
L1024 Continuous Form Laser Printer
L1024 Continuous Form Laser Printer
Maintenance Manual
R
P/N 704792001, Rev C
WARNING This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense. Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. The manufacturer is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by unauthorized changes or modifications to this equipment. Unauthorized changes or modifications could void the users authority to operate the equipment. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. The input/output (I/O) cable must be shielded for the printer to comply with FCC rules and regulations Part 15 governing the radiation limits for Class A equipment. This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the radio interference regulations of the Canadian Department of Communications. Ce matriel numrique nmet pas de bruits radiolectriques suprieurs aux limites fixes pour les appareils numriques de la Classe A dans le rglement sur le brouillage radiolectrique publi par le Ministre des Communications du Canada. Printronix, Inc. makes no representations or warranties of any kind regarding this material, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix, Inc. shall not be held responsible for errors contained herein or any omissions from this material or for any damages, whether direct, indirect, incidental or consequential, in connection with the furnishing, distribution, performance or use of this material. The information in this manual is subject to change without notice. This document contains proprietary information protected by copyright. No part of this document may be reproduced, copied, translated or incorporated in any other material in any form or by any means, whether manual, graphic, electronic, mechanical or otherwise, without the prior written consent of Printronix, Inc. All rights reserved. Revision C. September, 1997.
Trademark Acknowledgements
Printronix is a registered trademark of Printronix, Inc.
COPYRIGHT 1996, 1997 PRINTRONIX, INC.
Table of Contents Chapter 1 Introduction

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Technicians . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Technicians . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11 11 13 13 13 14 14 15
Chapter 2 Clamshell
Clamshell Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Top Cover, Latch, and LED Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Catch Release Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Left and Right Catch Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Miscellaneous Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Left and Right Hinge Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Clamshell Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Top Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Catch Release Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Left and Right Catch Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Clamshell Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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Chapter 3 OPC Drum Unit Subsystem

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 31 32 32 32
Chapter 4 Developer Subsystem

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 41 43 43 43
Chapter 5 Transfer Subsystem

Transfer Charger Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Transfer Corona Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Engagement Lever Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Transfer Charger Subsystem Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Transfer Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 Engagement Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Chapter 6 Paper Feed Subsystem

Paper Feed Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Paper Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Tension Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Drive Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Tractor Assembly and Tractor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 Tension Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616 Drive Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622 Tractor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
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Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Paper Guide and Paper Empty Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
629 630 631 631 632 632 632
Chapter 7 Fuser Subsystem

Fuser Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Fuser Heat Shield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Fuser Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 Fuser Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
Chapter 8 Power Supplies

Power Supplies Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Input Voltage Conversion and Fuse Replacement . . . . . . . . . . . . . . . . . 817 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824 High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 831 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 831 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 834
Chapter 9 Controllers and Floppy Disk Drives

Data Controller Board Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Engine Controller Board Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Stepper Motors Controller Board Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Floppy Disk Drives Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Data Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
Table of Contents
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper Motors Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floppy Disk Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expansion C/T Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
911 915 915 916 916 916 917 917 924 925 925 926 926 930 930 930 931
Chapter 10 Control Panel

Control Panel Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 103 103 103 106 106 107 107 107
Chapter 11 Laser Scanning Unit (LSU) Subystem

LSU Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 LSU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Erase LED Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 LSU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1110 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111 Erase LED Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112 Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114
Chapter 12 Covers, Frame, and Backplane Board

Covers Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Left Side Frame Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Right Side Frame Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Bottom Frame Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1210 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1212 Left Side Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1213
vi
Table of Contents
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Side Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backplane Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1213 1217 1217 1217 1218 1218 1226 1226 1226 1227 1227 1246 1246 1246 1247 1247 1251 1252 1252
Chapter 13 Troubleshooting Guide

Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Power-Up Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Print Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Checking the Power-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Guide to Imaging Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Index to Imaging Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Detailed Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Guide to Error Mesages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1326 Operator-correctable Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 1326 Service Call Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1327 Detailed Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1329 01 CLOSE THE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1329 02 LOAD PAPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1329 03 ADD TONER AND CHK WASTE BOTTLE . . . . . . . . . . . . . . . . . . . 1330 04 INSTALL TONER CUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1330 05 INSTALL OPC DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1331 06 CLEAR JAM AT FUSER INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1331 07 CLEAR JAM AT FUSER EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1331 08 CLEAR JAM NEAR TOF LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1331 09 CHECK TOF LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1331 19 SPEED CTL ERRCheck Paper Path . . . . . . . . . . . . . . . . . . . . . . 1331 25 ENCODER FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1332 15 FUSER FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1336 16 FUSER FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1336 17 FUSER FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1336 18 FUSER FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1337 23 THRMISTR FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1337 24 THRMISTR FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1338 26 HEATER FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1338 27 HEATER FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1338 28 BEAM DET FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1339 29 LSU FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1340 30 LSU FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1340 31 LSU FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1340
Table of Contents
vii
32 MISPRINT ERRORCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . 33 REPLACE EEPRMCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . 34 REPLACE OPC DRUMCall Service . . . . . . . . . . . . . . . . . . . . . . . 35 EC CKSUM FAILCall Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOF REGISTRATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1341 1341 1341 1341 1342
Appendix A Printer Specifications Appendix B Wire Data Appendix C Continuous Form Stacker
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2 Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C16 The Basic Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C16 The Tabletop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C17 The Paddle Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C19 The Upper Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C21 The Paddle Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C22 The Paper Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C23 The Front and Rear Paper Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C24 The Left and Right Vertical Frame Braces . . . . . . . . . . . . . . . . . . . . . . . C26 The Left and Right Upper Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C28 The Upper Drive Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C33 The Cable Clamp Screw Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C34 The Paper Shelf (with cable installation) . . . . . . . . . . . . . . . . . . . . . . . . . C35 Stacker Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C39
Appendix D Principles of Operation
viii
Table of Contents
Chapter 1 Introduction
Scope
This manual covers service and parts for the L1024 24-ppm continuous-form laser printer. Each section covers one major subassembly of the printer, in the following order: S Overview S Mechanical Explanation S Electronics Explanation (if appropriate) S Subassembly Removal from the Printer and Disassembly S Subassembly Reassembly and Replacement in the Printer S Adjustment (if needed) S Limited Troubleshooting (See also Chapter 13 for more troubleshooting)
Conventions
The use of LEFT and RIGHT always assumes you are viewing the front of the printer. For instance, the control panel is on the RIGHT side of the front of the printer. Notes and Notices that you need to pay special attention to are presented in the following way: WARNING: CAUTION: NOTE: Possible danger to you or the user. Possible equipment or data damage may occur. Extra information for you to consider.
Related Documents
This manual does not explain how to operate or configure the printer. For that information, refer to the Operators Guide and Setup Guide that accompany the printer.
Unit Overview
The L1024 is a 24-ppm continuous-form laser printer. It contains an internal engine controller and an internal data controller plus a floppy disk drive. The printer includes the major subassemblies shown in Figure 11.
11
CLAMSHELL LSU (LASER SCANNING UNIT)
HIGH VOLTAGE SUPPLY
LED ARRAY
LEFT FRAME TRACTOR TRANSFER OPC DEVELOPER
FUSER ROLLER ASSEMBLY FUSER BASE
MOTOR
STEPPER MOTOR & CONTROL BOARD HOUSING LOW VOLTAGE SUPPLY
BASE PAN TENSION ROLLER
MAIN DRIVE CONTROL PANEL ENGINE CONTROLLER BOARD BACKPLANE BOARD BOTTOM FRAME
RIGHT FRAME
DATA CONTROLLER BOARD BOTTOM COVER
Figure 11. Major Subassemblies.
12
Maintenance Users
The printer is designed so that the user can perform the following maintenance tasks without calling a service technician: S Removing and replacing the Toner Cartridge S Removing and replacing the Waste Toner Container S Replacing the Fuser Felt Wiper S Cleaning the Fuser Heat Roller S Cleaning the Transfer Corona Wire S Cleaning the Charge Corona Wire S Removing and replacing the OPC Drum Unit S Removing and replacing the Developer Unit S Removing and replacing the Ozone Filter S Removing and replacing the Fuser Unit When you are called to service the printer, check these items to be sure that the owner is replacing them according to the schedule below. This user maintenance schedule provides the owner with the best quality printing.
Service Technicians
Service personnel will provide all other maintenance on these printers according to warranty and service agreements. WARNING: Since this unit uses laser light, even though the power is less than 1 milliwatt at 780 nm, it is wise to protect your eyes whenever the top of the printer (clamshell) is open and the Laser Scanning Unit (LSU) is exposed and functioning. We recommend that you wear protective eyewear capable of attenuating laser light at 780 nm to safe levels or cover the LSU cover glass to prevent the laser light from escaping during servicing.
13
Cleaning Methods
Cleaning kits are provided in the Developer Kits, as well as being sold separately. These kits include cotton swabs, several wet wipe tissues in foil pouches, a corona wire cleaning brush, and instructions. Users and service personnel are encouraged to use them on the schedule shown below.
Users
Users should perform the following actions at the frequencies listed below: When Refilling the Toner (approximately every 8,000 pages) S Replace the Waste Toner Container. S Replace the Fuser Felt Wiper. S Clean the Fuser Heat Roller. S Clean the Transfer Corona Wire. S Clean the Charge Corona Wire. When Replacing the OPC Drum Unit (approximately every 30,000 pages) S Clean inside the printer as needed. When Replacing the Developer Unit (approximately every 100,000 pages) S Replace the Ozone Filter. S Clean the Fuser Heat Roller. S Clean the Transfer Corona Wire. S Clean the Charge Corona Wire. When Using Label Paper and Regular Paper alternately S Clean the Tension Roller (after each 4,000 pages of labels printedsee the information on the next page). WARNING: Turn off power to the printer before cleaning it.
14
Service Technicians
Service personnel should perform the following actions at or before every 300,000 pages: S Clean the LSU Cover Glass. S Clean other parts as needed inside the printer, including vacuuming the interior of the printer. WARNING: NOTE: Turn off power to the printer before cleaning it. The inside of the printer should be cleaned and vacuumed including special attention to paper dust on the fuser fan motor. This should be done whenever the printer is serviced, or at 300,000 pages, whichever comes first.
15
The following table lists the items needing periodic cleaning and the recommended cleaning procedures:
Cleaning Area Tension Roller
Frequency 4,000 pages (especially if using regular paper after using labels)
Cleaning Tool Wet Wipe Tissue
Method Turn off the printer. Open the top and front covers of the printer. Remove the OPC Drum Unit and the Developer Unit (refer to the Setup Guide). Wipe the tension roller with a wet wipe tissue while rotating the black gear on the right side as shown in the illustration below.
Figure 12. Cleaning the Tension Roller
(Continued on next page)
16
Cleaning Area Fuser Heat Roller; Transfer Corona Wire; Charge Corona Wire Inside Cleaning
Frequency When replacing Felt Wipers and when replacing Developer Unit
Cleaning Tool Refer to the Setup Guide.
Method Refer to the Setup Guide.
30,000 pages
Wet Wipe Tissue
Remove paper powder and toner from the areas listed below: S Transfer Charger around the mylar sheet (wipe the mylar first, then use the brush for the wire) S Around the Tractor S Inside the right cover S High Voltage Power Supply cover S Fuser paper guide S Transfer paper guide S Paper guide inlet S Front paper guide (if installed)
LSU Cover Glass
300,000 pages
Cotton Swab and Rubbing Alcohol
Wipe the LSU Cover Glass with a cotton swab containing anhydrous rubbing alcohol. Rub the glass in one direction only (either from right-to-left or from left-to-right). Repeat this process, using a new cotton swab each time, until the glass is completely clean.
17
18
Chapter 2 Clamshell
Clamshell and Subassemblies
Chapter 2 Clamshell
21
2.1 Clamshell Parts List 2.1.1 Top Cover, Latch, and LED Assemblies
Callout 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 21 22 23 31 26 27 28 29 30 32 33 34 Name Top Cover and Latch Assembly Top Cover Assembly Cover, Top Seal, Short Seal, Medium Seal, Long Toner Dust Baffle Screw, PPH, CLFW, M3x8, Zinc (2) Latch Assembly Spring, Torsion, Lower Latch Lever, Release Button, Release Shaft, Latch (2) Button, Locking Shaft, Locking Frame, Latch E-Ring, 3mm I.D., Zinc (2) E-Ring, 4mm I.D., Zinc (2) Spring, Torsion, Upper Latch Screw, PPH, CLFW, M3x6, Zinc (2) Screw, PPH, CLFW, 3x6mm, Zinc (11) LSU Base Plate Assembly LSU Base Plate Cover Felt, Clamshell Fuser Bushing, LED Wire Harness (not shown) Erase LED Assembly Cover, LED Assembly Mount, LED, Plastic Board Assembly, LED Screw, PPH, PTC, 3x8mm, Zinc (4) Cable, LSU LSU Seal, LSU Drum Vendor Part No. Printronix Part No. 202104501 200864001 702817001 200495001 703108001 200533001 702820001 200532001 702819001 200531001 702818001 200563001 702730001 030129308 200489554 702690001
071151004 071051006 030130306 030130306 202165001 202166001 202167001 200542501 200541001 702724001
030129308 202294551 202118551 202575001
22
Chapter 2 Clamshell
1 Ref
20 2
9 1
Top Cover
2 Ref
10 1 13 2 19 1
Latch Assembly Detail 11 1 14 1 33 1 34 1 8 2 12 1
7 1 4 1
5 1
6 1 20 8
3 1
15 1
16 1
17 2 18 2
32 1
21 Ref 20 3 26 1 23 1 25 1 22 1
20 2
LED Assembly
28 1 29 1 LED Array Assembly Detail 30 4
27 1
26 Ref
Top Cover, Latch, and LED Assemblies
Chapter 2 Clamshell
23
2.1.2 Catch Release Assembly

Callout 1 2 3 4 5 6 Name Catch Release Assembly Frame, Catch Release Lever, Release, Right Lever, Release, Left Shaft, Clamshell Locking Pin, Spring, 2x10mm, SS (2) Vendor Part No. Printronix Part No. 200870501 702825001
200980001 080199110
2.1.3 Left and Right Catch Assemblies

Callout 7 8 9 10 11 12 13 9 10 11 Name Catch Assembly, Left Clamshell Catch, Left Shaft, Clamshell Catch E-Ring, 5mm I.D., Zinc Screw, PPH, CLFW, 3x8mm, Zinc (2) Catch Assembly, Right Clamshell Catch, Right Shaft, Clamshell Catch E-Ring, 5mm I.D., Zinc Screw, PPH, CLFW, 3x8mm, Zinc (2) Vendor Part No. Printronix Part No. 200872501 702831001 200523001 071151008 030130308 200871001 200523001 071151008 030130308 702829001
2.1.4 Miscellaneous Components

Callout 14 15 16 17 18 19 Name OPC Retaining Spring (2) Clamshell Frame, Right Clamshell Frame, Left Hinge Assembly, Left Hinge Assembly, Right Screw, PPH, CLFW, 3x6mm, Zinc (6) Vendor Part No. Printronix Part No. 202164001 202163001 200967002 201231001 030130306
704539114 704539115
24
Chapter 2 Clamshell
4 1
5 1
1 Ref Catch Release Assembly
19 4
6 2 3 1
9 1 7 Ref Left Catch Assembly 11 2 2 Ref
10 1
2 1
10 1
9 1
12 Ref Right Catch Assembly
19 2 8 1 16 1 14 2 15 1 13 1 11 2 18 1 Left Hinge Assembly Right Hinge Assembly
17 1
Catch Assemblies
Chapter 2 Clamshell
25
2.1.5 Left and Right Hinge Assemblies

Callout 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 Name Frame, Clamshell, Left Frame, Clamshell, Right Hinge Assembly, Left Hinge Assembly, Right Hinge Assembly, Shaft/Bracket Bracket, Hinge Shaft, Hinge Spring, Compression, Hinge Hinge, Slide Retention Plate Frame, Clamshell Hinge CE-Ring, 7mm I.D., Zinc Screw, PPH, CLFW, 3x6mm, Zinc (1) Screw, PPH, CLFW, 3x6mm, Zinc (2) Shaft, Pivot Collar, Pivot Shaft Spring, Compression, Hinge Tension Shaft, Locking Screw, PPH, IW, 4x6mm, Zinc E-Ring, 3mm I.D., Zinc Vendor Part No. Printronix Part No. 202163001 202164001 200967002 704539114 201231001 704539115 200605001
200607001 200609001 200610001 200611001 072151012 030130306 030130306 200608001 200612001 200613001 200614001 030131406 071151004
26
Chapter 2 Clamshell
4 1
3 Ref
5 1
15 1 13 1
12 1 11 2
6 1
1 1
7 1
17 1
2 Ref
10 1
14 1 16 1 11 1
8 1
9 1
NOTE: This is the left side hinge. The right side hinge is a mirror image of the left side hinge.
Hinge Assemblies
Chapter 2 Clamshell
27
2.2 Clamshell Overview 2.2.1 Mechanical

The Clamshell consists of the following basic subassemblies: A. Top Cover Assembly. This includes: S The Top Cover. S The Toner Dust Baffle. The Baffle is attached to the Top Cover Assembly. With the Clamshell closed, the Baffle is positioned over the waste toner outlet from the OPC Drum Unit. The Baffle traps any waste toner dust and prevents contamination of the engine. S Latch Assembly. The Latch Assembly is attached to the Top Cover and is used to open the printer Clamshell. S Catch Release Assembly. The Catch Release Assembly releases the Clamshell Latches on each Side Frame from the shafts on the Clamshell Catches. S Left and Right Catch Assemblies. The Catch Assemblies hold the Clamshell closed using the Clamshell Latch. The Right Catch Assembly also acts as the Cover Open Interlock. S Clamshell Hinges. The two Hinges allow the Clamshell to rotate upward for insertion of paper, replacement of consumables, and service. B. LSU Base Plate (discussed in more detail in Chapter 11, Laser Scanning Unit Subsystem). This includes: S The LSU. The Laser Scanning Unit generates the laser light, which writes a picture of the page to be printed onto the OPC drum. It is discussed in detail in Appendix C. S The LED Erase Assembly. The Erase Assembly erases the charge on the OPC drum by exposing it to light. The drum is erased prior to being charged by the LSU. The LED Erase Assembly is discussed in detail in Appendix C.
28
Chapter 2 Clamshell
2.2.2 Electrical
All electrical connections to the Clamshell are via a cable from the Backplane Board to the LSU that passes through the Right Hinge Assembly. The cabling block diagram for the Clamshell is shown below. See Appendix B for a complete electrical block diagram.
Backplane Board
J4
1 +12V 3 5 7 9 11 13 /QLED +24 BGND /PMON /PMRDY +5 DGND /BD +5 DGND /LDON /LVIDEO LVR
TO LSU
Block Diagram 21. Top Cover Electrical
Chapter 2 Clamshell
29
2.3 Top Cover Assembly 2.3.1 Removal and Disassembly

1. Open the Clamshell and remove 3 Screws from the Clamshell Frame (see Figure 21), then lift the front of the Top Cover first to help disengage the LSU Locking Tabs from the rear of the Cover. See Detail 21.
210
Chapter 2 Clamshell
Latch Removal Detail
Top Cover
Step 4
Step 3
Step 5
Clamshell Frame
Step 1
Figure 21. Top Cover Disassembly
Chapter 2 Clamshell
211
1. Lift Front Cover, then disengage rear Locking Tabs.
2. Depress tab to remove Hinge Cover.
Detail 21. Removing Top Cover and Hinge Covers
212
Chapter 2 Clamshell
2. Remove either Hinge Cover by pressing the lower Locking Tab with a small screwdriver and removing the Hinge Cover by lifting it upward. See Detail 22. NOTE: The Clamshell Frame may need to be closed for removal of the Hinge Covers.
Repeat Step 2 for the other hinge cover. 3. Remove 2 screws, then remove the Toner Dust Baffle. See Figure 21. 4. Remove 2 screws, then remove the Latch Assembly from the Top Cover. See Figure 21. 5. Remove the Toner Seals from the Top Cover only if absolutely necessary. See Figure 21.
2.3.2 Reassembly and Replacement

Reverse Steps 1 through 5 listed above. NOTE: When reinstalling the Top Cover onto the Clamshell, make sure the Latch Assembly is properly oriented with the Release Lever. See Detail 22 on page 215.
2.3.3 Adjustment
No adjustment of the Top Cover Assembly is necessary.
2.3.4 Troubleshooting
See Chapter 13 for troubleshooting information.
Chapter 2 Clamshell
213
2.4 Latch Assembly 2.4.1 Removal and Disassembly

1. Open the Clamshell and remove 2 screws, then remove the Latch Assembly. See Figure 21. 2. Remove 1 E-ring, then slide the Latch Shaft free of the Release Lever. This frees the Release Lever and Lower Latch Spring from the Release Button. See Figure 22.
Step 2
Step 3
Step 4
Figure 22. Latch Assembly Disassembly 3. Remove the other E-ring, then slide the Latch Shaft free of the Latch Frame. This frees the Latch Frame, Locking Button, Release Button, and Upper Latch Spring from one another. See Figure 22. 4. The Locking Shaft can be removed from the Latch Frame by removing the E-ring from either end of the Shaft and sliding it off of the Frame. See Figure 22
214
Chapter 2 Clamshell

Reverse Steps 1 through 4 listed above, and also refer to Detail 22 below. NOTE: When reinstalling the Latch Assembly onto the Top Cover, make sure the Latch Assembly is properly oriented with the Release Lever. See Detail 22.
CORRECT LATCH RELEASE POSITION
Detail 22. Correct Latch Release Position
2.4.3 Adjustment
No adjustment of the Latch Assembly is necessary.
Chapter 2 Clamshell
215
2.5 Catch Release Assembly 2.5.1 Removal and Disassembly

1. Open the Clamshell, remove 3 Screws from the Clamshell Frame, then lift the front of the Cover. This helps disengage the Locking Tabs of the LSU from the rear of the Cover. See Figure 21 and Detail 21. 2. Remove 4 attachment screws, then remove the Catch Release Assembly from the Clamshell Frame. See Figure 23.
216
Chapter 2 Clamshell
Step 2, page 219
Catch Release Assembly
Step 2 Step 3
Step 4, page 219 Step 5, page 219
Step 3, page 219
Left Catch Right Catch

Step 2, page 219 Step 2, page 219
Figure 23. Catch Release Assembly Removal
Chapter 2 Clamshell
217
3. Remove the Spring Pin from the desired Release Lever, then slide it off of the Shaft. The Shaft can now be slid free of the Frame.

Reverse Steps 1 through 3 listed above. NOTE: When reinstalling the Top Cover onto the Clamshell, make sure the Latch Assembly is properly oriented with the Release Lever. See Detail 22.
2.5.3 Adjustment
218
Chapter 2 Clamshell
2.6 Left and Right Catch Assemblies 2.6.1 Removal and Disassembly
1. Open the Clamshell, remove 3 Screws from the Clamshell Frame, then lift the front of the Cover. This helps disengage the Locking Tabs of the LSU from the rear of the Cover. See Figure 21 and Detail 21. 2. Remove 4 Screws from the corners of the LSU Base Plate, then remove 1 Screw from the outside of each Clamshell Frame. This loosens the LSU Base Plate so that the Catches can be removed from the Clamshell Frames. See Figure 23. 3. Remove 2 screws, then remove the Right Clamshell Catch. 4. Remove 2 crews, then remove the Left Clamshell Catch. 5. Remove 1 E-ring, then remove the Shaft from either Catch Assembly.

Reverse Steps 1 through 5 listed above. NOTE: When reinstalling the Top Cover onto the Clamshell, make sure the Latch Assembly is properly oriented with the Release Lever. See Detail 22.
2.6.3 Adjustment
Chapter 2 Clamshell
219
2.7 Clamshell Hinges 2.7.1 Removal and Disassembly

1. Place the printer on a phone book or other similar item so that the Bottom Cover edges are not resting on the item. Press gently to release the 2 Locking Tabs on the right side of the Bottom Cover, then gently lower this side. See Detail 23. Slide the Bottom Cover slightly to the right to release the locking tabs on the left side, then lower the Bottom Cover away from the printer and over the phone book.
Bottom Cover Locking Tabs
Detail 23. Bottom Cover Removal 2. Remove the printer from the phone book and position the printer so that the rear of the Base Plate extends over the edge of the work surface. Remove 1 Screw from the bottom of the
220
Chapter 2 Clamshell
Base Plate for each Hinge. See Figure 24. Remove 1 Screw from the top of each Hinge, then remove the entire Clamshell Assembly from the printer. CAUTION: Since the LSU Cable is still connected to the printer, the Clamshell will have limited movement. Be careful not to damage the LSU, the LSU Cable, or the Clamshell Frame.
Step 2
Step 4 Step 5
Step 6 NOTE: This is the left side hinge. The right side hinge is a mirror image of the left side hinge. Step 3 Step 2
Figure 24. Clamshell Hinge Removal
DISASSEMBLY (See Figure 24)

3. Remove 1 Screw from the Hinge Frame, then remove the Retention Plate. The Hinge Slide can now be slid free from the Hinge Frame. 4. Remove 1 CE-ring from the Slide, then remove the Slide and Hinge Spring from the Hinge Shaft. 5. Remove 1 E-ring from the Clamshell Frame, then remove the Locking Shaft, Shaft Collar, and Bracket Assembly from the Hinge Assembly.
Chapter 2 Clamshell
221
6. Remove 1 Screw and the Tension Spring, then remove the Pivot Shaft from the Assembly to free the Hinge Frame from the Clamshell Frame. NOTE: The steps above can be performed for either Hinge Assembly.

Reverse Steps 1 through 6 above.
2.7.3 Adjustment
Adjust the spring tension (on the side of the hinge) so that when the Clamshell is opened fully and released, the Clamshell falls to a 30 angle and then stops. This adjustment prevents the Clamshell from injuring the fingers of operators or service personnel. Spring Retention Plate
222

Spring Tension Adjustment Screw Figure 25. Clamshell Hinge Adjustment Chapter 2 Clamshell

3.1 Overview
The OPC Drum Unit is a user-replaceable consumable. It has a life of around 30,000 pages. It receives the laser light image of the page from the LSU, transfers toner from the developer to the OPC drum to form this image, and allows the toner image to be transferred to the page prior to fusing. See Figure 31. This unit is factory assembled and factory adjusted. No field adjustments are required.
Figure 31. OPC Drum Unit
3.2 Removal and Disassembly

To remove the OPC Drum Unit from the printer, first open the printer top cover. Then, simply lift the unit out of the printer. See Figure 32. CAUTION: When removing the OPC Drum Unit from the printer, be careful not to spill toner from the waste toner screw (located on the left side of the unit).
31
No disassembly is required.
OPC Drum Unit
Figure 32. Removing the OPC Drum Unit
3.3 Reassembly and Replacement

No reassembly is required. To install an OPC Drum Unit, first place the unit in the printer. Then, ensure that the unit is fully seated so that its contacts on the right side are properly set, and so that the Waste Toner Auger Seal opens and fits properly over the Waste Toner Container. See Figure 32.
3.4 Adjustment
The OPC Drum Unit is adjusted at the factory; no field adjustments are required.
3.5 Troubleshooting
32

4.1 Overview
The Developer Unit consists of a hopper containing toner and carrier, plus a magnet roller. The magnet roller provides measured amounts of toner to the OPC Drum Unit, for developing the page image. See Figure 41. This unit is factory assembled and factory adjusted. No field adjustments are required.
Figure 41. Developer Unit
4.2 Removal and Disassembly

To remove the Developer Unit from the printer, first open the top and front covers of the printer. Then, unlock the green locking levers on each side of the Developer Unit, and lift the unit out of the printer along the plastic rails on each side. See Figure 42. CAUTION: When removing the Developer Unit from the printer, be careful not to turn the unit over, because toner may spill out of the unit.
41
No disassembly is required.
Figure 42. Removing the Developer Unit
42
4.3 Reassembly and Replacement

No reassembly is required. To install a Developer Unit, first open the top and front covers of the printer. Then, slide the Developer Unit into the printer along the plastic rails on each side, until the unit is fully seated in the printer. Lock both of the locking tabs. If the Developer Unit that you are installing is a new one, follow the instructions in the Operators Guide for replacing carrier and toner. See Figure 42.
4.4 Adjustment
The Developer Unit is adjusted at the factory; no field adjustments are required.
4.5 Troubleshooting
43
44
Transfer Charger
51
5.1 Transfer Charger Parts List

Callout 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Name Transfer Charger Assembly Base, Transfer Charger Transfer Charger Assembly Frame Assembly, Transfer Charger Frame, Transfer Charger Swing Shaft Damper, PVC (2) Transfer Corona Assembly Screw, PPH, CLFW, Zinc, 3x8mm (2) Paper Guide, Plastic, Rear Brush, Static Discharge Screw, PPH, IW, Chrome, 3x6mm (2) Shaft, Transfer Charger E-Ring, 3.0mm I.D., Chrome Spring , Compression,Transfer Charger (2) Paper Guide, Plastic, Front Paper Guide, Transfer Charger Screw, PPH, CLFW, M3x6, Zinc (6) Paper Guide, Lower (Shown in this view, not part of this assembly) Vendor Part No. Printronix Part No. 202140501 704539063 201235001 202142501 200554552
202143501 030130308 202148001 202147551 030231306 200553001 071251004 200555001 202141001 200551001 030130306 202149001
704539068
52
9 2 1 Ref 12 2 8 1
17 1
14 2 5 1 4 Ref 7 2 6 1 11 1 16 1
13 1
18 4 18 2 19 1 15 2 2 1 10 1
3 Ref
Transfer Charger Assembly
53
5.2 Transfer Corona Parts List

Callout 1 2 3 4 5 6 Name Transfer Corona Assembly Wire, Transfer Corona Cover, Transfer Corona (2) Spring, Extension, Transfer Corona Housing, Transfer Corona Mylar Strip, Transfer Corona Vendor Part No. Printronix Part No. 202143501 704539064 202144001 202145001 200617001 200618001 202146001
3 2 2 1 6 1
1 Ref
5 1
4 1
Transfer Corona Assembly
54
5.3 Engagement Lever Parts List

Callout 1 2 3 4 5 6 7 8 Name Engagement Lever Assembly Guide, Engagement Lever (2) Engagement Lever Unit Pulley, Cam Lever Shaft, Pulley, Cam Lever Lever, Engagement Spring, Extension, Engagement Lever Screw, PPH, CLFW, 3x6mm, Zinc (2) Vendor Part No. Printronix Part No. 200502501 702701001 200500001 200499551
200501001 030130306
6 1
1 Ref
7 1
8 2
4 1
5 1 2 2
3 Ref
Engagement Lever Assembly
55
5.4 Transfer Charger Subsystem Overview 5.4.1 Mechanical

The following is a description of the major mechanical parts of the Transfer Subsystem and their functions. Engagement Lever. This is attached to a cam of the Fuser Cam Shaft. The cam pulls the Transfer Charger carriage away from the paper when the printing process is finished and the Fuser opens. Transfer Charger Carriage. This carriage raises the Transfer Corona up and down during the printing process. It contains the Transfer Corona, Static Brush, and Paper Guide, and is driven by the Engagement Lever. Static Brush. This brush removes the static charge that is built up during the transfer process. Transfer Corona. This is a 60 m gold-plated tungsten wire that, with an electric charge, pulls toner, in the form of a developed image, from the OPC drum to the paper. Plastic Paper Guide. This guide sets the paper to the correct height from the transfer corona.
High Voltage Power Supply
Low Voltage Power Supply
Cover Switch
CN3
Transfer Corona Drum Switches 60 m wire
Figure 51. Physical Arrangement of the Transfer Subsystem
56
5.4.2 Electrical
The transfer system has a very limited electrical function. It includes only the transfer corona. See Block Diagram 51.
Backplane Board
1 J10
+24VB /CHARGE /DEVELOPER /TRANSFER BGND
1 HIGH VOLTAGE POWER SUPPLY
OPC
TRANSFER CORONA
6 DEVELOPER BIAS +5
1 J9 4
/WASTE TNRLOW DGND
1 J1 4 TONER SENSOR BOARD
CN1 CN2
TONER SENSOR DEVELOPER
Block Diagram 51. Transfer Subsystem Electrical Components, Transfer Corona The transfer corona is a small (60 m) wire that is charged to +4,600 volts (100 volts) DC. The input for the Transfer Corona (Block Diagram 51) is connector pin CN3 from the High Voltage Power Supply (HVPS). This connector pin is on a spring-loaded connector that is located under the left side of the Transfer Charger, near the Waste Toner Cup. NOTE: The Corona Baseplate is grounded to the Charger Baseplate.
When the /TRANSFER signal goes low (zero volts), the HVPS turns on the voltage to the Transfer Corona Wire. This voltage then causes the developed image to transfer from the OPC Drum to the paper.
57
5.5 Transfer Charger 5.5.1 Removal and Disassembly

1. Open the Clamshell and remove the OPC and Developer Units, and any paper that may be present in the Printer. 2. Remove the Front Plastic Paper Guide from the Transfer Charger by pressing down on the center and ends, then sliding it to the left. This disengages the Locking Tabs, allowing the Paper Guide to be easily removed. See Figure 53.
58
Step 6
Step 3
Step 5
Step 7
Step 8
Step 2
Step 4
Step 4
Figure 53. Transfer Charger
59
3. Remove the Transfer Charger Paper Guide by gently pressing the Release Tabs at the rear of the Guide toward the front of the Printer. Lift the rear of the Guide to clear the Tabs of the Slots, and release the Front Tabs by rotating the Guide toward the front of the Printer. 4. Remove 4 Screws from the bottom of the Transfer Charger. Remove the Charger from the Printer by lifting the front of the unit and rotating it toward the rear of the Printer. This makes it easier to disengage the Swing Shaft from the Engagement Lever. See Detail 51. NOTE: The Transfer Corona Assembly can be removed from the Transfer Charger without removing the Transfer Charger from the Printer. To do this, first remove the Front Plastic Paper Guide per the instructions in Step 2 above. Then, proceed to Step 5 below.
Swing Shaft
Detail 51. Loosening the Transfer Charger 5. Remove the Static Brush and Rear Plastic Paper Guide by removing 2 Screws. NOTE: When reinstalling the Static Brush, make sure the Brush Frame is in front of the Locking Tab for the Corona Assembly. See Detail 52.
510
Detail 53
Corona Neck Is Placed Under Retaining Tab
DETAIL 52
Static Brush Is Placed In Front Of Retaining Tab
Detail 52 and 53. Removing the Static Brush and Rear Paper Guide; Corona Contact and Locking Tab 6. Transfer Corona Assembly: a. Remove 2 Screws and lift the Corona Assembly up slightly while sliding it to the left to disengage the Locking Tabs. See Figure 54.
511
Step 6B
Step 6C
Step 6A
Step 6B Step 6D
Step 6A
Figure 54. Transfer Corona Assembly NOTE: When installing the corona assembly, make sure the neck of the corona contact is under its locking tab. See Detail 53.
b. Remove the 2 Covers by gently releasing the Locking Tabs with a screwdriver. CAUTION: c. The Tabs are extremely fragile and can be easily broken.
To remove the Corona Wire, gently pull on the small Eyelet at the opposite end of the Wire from the Spring, and remove the small Eyelet from its Post. CAUTION: The Wire is only 60 m thick and can be easily broken. Also, do not touch the wire, as fingerprints may cause it to fail.
d. Remove the large Eyelet from the Spring. NOTE: The Spring should be removed only if absolutely necessary.
7. Remove the E-ring on the left end of the Main Shaft and remove the Shaft. 8. Remove the Transfer Charger Frame from the Charger Base Plate.
512

5.5.3 Adjustment
No adjustment of the Transfer Charger Assembly is necessary.
513
5.6 Engagement Lever 5.6.1 Removal and Disassembly

1. Open the Clamshell, remove the OPC, Developer Unit and any paper present in the Printer. See Figure 55.
514
Step 5
Detail 56
Step 9
Cover overlaps tractor assembly side frame
Detail 55
Step 11
Step 8 Step 10
Step 6
Step 7
Figure 55. Engagement Lever Removal
515
(For Steps 2 through 4 following, refer to Figure 53 on page 59.) 2. Remove the Front Plastic Paper Guide from the Transfer Charger by pressing down on the ends of the Paper Guide and sliding it to the left. This disengages the Locking Tabs and the Paper Guide can then be easily removed. 3. Remove the Transfer Charger Paper Guide by gently pressing the Release Tabs at the rear of the Guide toward the front of the Printer. Lift the rear of the Paper Guide to clear the Tabs of the Slots, and release the Front Tabs by rotating the Paper Guide toward the front of the Printer. 4. Remove 4 Screws from the bottom of the Transfer Charger. Remove the Charger from the Printer by lifting the front of the unit and rotating it toward the rear of the Printer. This makes it easier to disengage the Swing Shaft from the Engagement Lever. See Detail 51 on page 510. 5. Remove the plastic Fuser Heat Shield. See Figure 55. 6. Remove the Lamp Connector Cover by removing 1 Screw and sliding the cover toward the fuser. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Figure 55 and Detail 54.
516
Detail 54. Removing the Lamp Connector
517
(For Steps 7 through 11 following, refer to Figure 55 on page 515.) 7. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Detail 55 in Figure 55. NOTE: Upon installation, the groove on the bottom of the Right Inside Cover should straddle the top edge of the right side of the Tractor Frame.
8. Remove the Tractor Encoder Cover by removing 1 Screw. NOTE: Upon installation, the groove on the bottom of the Encoder Cover should straddle the top of the left end of the Tractor Frame. See Detail 56 in Figure 55.
9. Remove the Tractor Paper Guide by removing 1 Screw from the center rear of the Tractor Frame. 10. Disconnect the Tractor Encoder Cable from the Connector on the Base Plate behind the Tractor. 11. Remove the Tractor by removing 3 Screws, then lifting the left end of the Tractor out first. This allows the the Encoder to clear the High Voltage Power Supply, and allows the Tractor room to move to the left so that the Tractor Stepper Motor can clear the Stepper Motor Board Frame. 12. Disconnect the Cable from the Tractor Stepper Motor and remove the Tractor from the Printer. 13. Remove 2 Screws, then remove the Engagement Lever from the Printer. 14. Remove the Engagement Lever Spring from the Rear Guide, then slide the Guide to the center of the Lever to remove it. The Front Guide can also be removed by sliding it to the center of the Lever.

Reverse Steps 1 through 14 listed above.
5.6.3 Adjustment
No adjustment of the Engagement Lever Assembly is necessary.
Ensure that the Engagement Lever moves freely and is engaged with the Fuser Cam and Pivot Shaft of the Transfer Charger.
518
Paper Feed Subsystem
61
6.1 Paper Feed Parts List 6.1.1 Paper Guides

Callout 1 2 3 4 5 6 Name Paper Guide, Lower Sensor, Paper Empty Wire Clamp, Paper Empty Sensor Screw, PPH, CLFW, 3x6mm (3) Guide, Paper Entry Guide, Paper Exit Vendor Part No. Printronix Part No. 202149001 704539068 202278551 704539053 202288001 030130306 202516551 202379001
4 3
1 1
2 1
6 1
3 1
5 1
Paper Guides
62
6.1.2 Tension Roller Assembly

Callout 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Name Tension Roller Assembly Frame Assembly, Tension Roller Frame, Tension Roller Shaft, Transfer Gear, Tension Roller Shaft, Drive Gear, Tension Roller Gear, Tension Roller (2) Gear, Transfer, Tension Roller Bushing, Tension Roller, Long Bushing, Tension Roller, Short Shaft Assembly, Tension Roller Shaft, Tension Roller Roller, Tension (2) Shaft, Plastic Pressure Roller Roller, Pressure, Plastic (4) Spring, Retaining, Plastic Pressure Roller E-ring, 2mm I.D., Zinc (2) E-ring, 4mm I.D., Zinc (3) Pin, Spring, 1.6x10mm, Steel Screw, PPH, CLFW, 3x6mm, Zinc (2) Vendor Part No. Printronix Part No. 202100501 202101551
200567001 202103001 201289002 201290001 202106551
202107002 202108001 202109001 071151002 071151006 080661003 030130306
63
9 Ref
18 1 10 1
11 2
15 1
13 2
14 1
16 1 12 1 7 1 13 2 15 1
1 Ref 2 1 3 1
18 1 4 1
5 1
19 Ref 8 1 5 1 17 1 6 1
16 2
Tension Roller Assembly
64
6.1.3 Drive Gear Assembly

Callout 1 2 3 4 5 6 37 40 7 8 9 10 11 12 10 12 13 14 15 16 17 18 19 12 20 21 22 23 24 25 11 12 23 26 27 28 29 11 12 30 31 32 32 33 34 Name Drive Gear Assembly Frame Assembly, Drive Gear Frame, Drive Gear Shaft, Gear, Center Shaft, Gear, Lower Stepper Motor Assembly, Drive Gear Cable, Stepper Motor, Drive Gear Stepper Motor, Main Gear, Transfer, Inner Shaft Assembly, Main Gear Shaft, Gear, Main Ball Bearing, Gear Shaft Pin, Spring, 2x12mm, SS E-ring, 4mm I.D., Chrome Ball Bearing, Gear Shaft E-ring, 4mm I.D., Chrome (5) Gear, Transfer, Lower Seal, Ball Bearing Gear Assembly, Developer Drive Ball Bearing, Gear Shaft (2) Gear, Drive, Developer Gear, Drive, Tension Roller Shaft, Assembly, Front Main Drive E-ring, 4mm I.D., Chrome Gear, Drive, Front Main Spacer, Metal Shaft, Gear, Front Main Bushing, Gear Shaft, Upper Gear, Transfer, Upper Shaft Assembly, Upper Gear Pin, Spring, 2x12mm, SS E-ring, 4mm I.D., Chrome Bushing, Gear Shaft, Upper Gear, Drive, Cleaner Roller Shaft, Gear, Upper Pin, Spring, 2x10mm, SS Shaft Assembly, Lower Gear Pin, Spring, 2x12mm, SS E-ring, 4mm I.D., Chrome Gear, Drive, OPC Shaft, Gear, Lower Bearing, Dry Bearing, Dry Gear, Main Drive, Rear E-Ring, 3mm I.D., Chrome (2) Vendor Part No. Printronix Part No. 202128501 202129551
202139501 202390551 202709551 200682002 200684001 200683551 080651112 071251006 200683551 071251006 200685001 200686001 200683551 200688001 200691001 071251006 200689002 200690001 202135001 200632001 200633001 080651112 071251006 200632001 200631001 200635001 080651110 080651112 071251006 200643001 200644001 202133001 202133001 200645001 071251004
65
6.1.3 Drive Gear Assembly (continued)

Callout 35 36 38 39 Name Screw, TPH, MT, 3x6mm, Zinc Screw, PPH, CLFW, 4x16mm, Zinc (4) Screw, PPH, CLFW, 3x6mm, Zinc (3) Screw, PPH, CLFW, 3x10mm, Zinc Vendor Part No. Printronix Part No. 035128306 030130416 030130306 030130310
66
1 Ref
29 Ref
11 2 31 1 35 1 22 1 30 1
32 1
26 1
28 1
11 1
27 1
23 1
12 1 19 Ref 34 1 7 1
24 1 23 1
20 1 21 1
15 Ref 14 1 10 2 17 1
12 1
12 3 39 1 25 Ref
4 1
33 1
32 1 40 1
12 1 6 Ref
12 3 10 1 11 1 13 1 5 1 3 1 38 3 2 Ref 8 Ref 9 1 10 1 34 1
37 1
18 1
36 4
Drive Gear Assembly
67
6.1.4 Tractor Assembly and Tractor Base

Callout 1 2 3 4 5 6 7 8 9 10 11 12 34 13 14 15 16 17 18 33 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Name Tractor Assembly Frame Assembly, Tractor Frame, Tractor Shaft, Centering Gear Gear, Centering Sensor, TOF Shaft, Guide, Tractor Tractor Assembly w/Arm, Left Tractor Assembly, Left Centering Arm, Left Screw, PPH, TF, 3x16mm (2) Tractor Assembly w/Arm, Right Screw, PPH, TF, 3x12mm (2) Tractor Assembly, Right Centering Arm, Right Stepper Motor Assembly, Tractor Stepper Motor, Tractor Bracket, Mounting, Tractor Motor Screw, PPH, CLFW, 3x6mm, Zinc (2) Cable, Stepper Motor, Tractor Shaft, Tractor Drive Bushing, Tension Roller, Long (4) Board, Tractor Encoder Wheel, Tractor Encoder Gear, Tractor Drive Shaft, Idler, Tractor Paper Support (2) Paper Guide, Tractor Screw, PPH, W/IW, 4x6mm, Zinc (2) Screw, PPH, W/IW, 3x6mm, Zinc (4) E-Ring, 4mm I.D., Chrome (5) E-Ring, 5mm I.D., Chrome Pin, Spring, 2x10mm, SS Screw, PPH, CLFW, 3x6mm, Zinc (3) Vendor Part No. Printronix Part No. 202150501 704539054 202151551
200450001 202153551 200566002 202380501 202381551 200452001 030129316 202382501 030129312 202383551 200451001 202742501 202155551 202156001 030130306 202392551 202157002 201289002 202158551 202159002 202160001 202161001 200456002 202125001 030131406 030131306 071251006 071251008 080660210 030130306
68
1 Ref
13 1
Front of Printer
12 Ref 34 2 25 2
27 2 23 1 33 1 15 Ref
29 1 31 1
14 1 10 1 11 2
9 1
8 Ref
28 2 16 1 32 3 5 1 18 2 4 1
30 1
19 1
Right Side of Printer

17 1
20 2 7 1 28 1
29 2
20 2
24 1
28 1 22 1
29 2
26 1
21 1 3 1 2 Ref
Rear of Printer
6 1
Left Side of Printer
Tractor Assembly and Tractor Base
69
6.2 Overview 6.2.1 Mechanical

The four units primarily responsible for positioning and moving media (paper or labels) are: S The Tension Roller Assembly S The Drive Gear Assembly S The Tractor Assembly S The Lower Paper Guide
6.2.2 Electrical
The electrical portion of the paper feed system consists of the following: S Drive Gear Assembly. The Stepper Motor of the Drive Gear Assembly is driven by the Stepper Motors Controller Board. S Tractor Assembly. The Tractor Stepper Motor is driven by the Stepper Motors Controller Board. S Tractor Encoder. The Tractor Encoder Board has two optical sensors that sense the 1/8 inch and 1/16 inch slots in the Encoder Wheels. These pulses are sent to the Engine Controller Board and are used to monitor and control print location and paper movement. S Paper Top Sensor (PTOP). This sensor is located at the center rear of the tractor. It is used to tell the printer when paper is present in the fuser. It is also used to indicate paper location when paper is being backfed into the printer. S Paper Empty Sensor. This sensor is located near the entry of the printer and tells the printer when there is no paper available to be fed in. Following is a block diagram of the paper motion elements. See Appendix B for a complete electrical block diagram.
610
MAIN STEPPER MOTOR (M1)
OZONE FAN
CN3
CN7
STEPPER MOTORS CONTROLLER BOARD

CN8 CN4
1 +24VB +24VB A B /A /B 6 1 COPEN 5 10 1 3
CN2
15 20 24 /OPC /NEWOPC TMRSG TMRPWR /OZNFAN /PRCL PHA1 PHB1 /PHA1 /PHB1 PDWN1 PHA2 PHB2 /PHA2 /PHB2 PDWN2 PHA3 PHB3 /PHA3 /PHB3 PDWN3 +5VL +24VB
CN6
1 2 1
CN5
6 8 +24VB +24VB A B /A /B
CN1
1 BGND BGND BGND +24 +24 +24 GND +5
PRFAN1 PRFAN2 J2 J3 JAM SENSOR EXIT JAM SENSOR PR CLUTCH FUSER STEPPER MOTOR (M3) J1
BACKPLANE BOARD
J4
FUSER BASE UNIT

J5
10
+5 1 /PRPOS /PRINIT /SCPUP /SCPDN PJAM EJAM /PRFAN DGND +24 10
J5
TRACTOR STEPPER MOTOR (M2)
PTOP SENSOR
COPEN 1 /OPC /NEWOPC TMRSG TMRPWR /OZNFAN /PRCL PHA1 PHB1 /PHA1 /PHB1 PDWN1 PHA2 PHB2 /PHA2 /PHB2 PDWN2 PHA3 PHB3 /PHA3 /PHB3 PDWN3 +5VL +24VB 24 +5 PFS8 PFS6 /PTOP DGND 1 3 5
J6
J2
ENCODER BOARD J1
J13
PEPWR
TRACTOR UNIT
PAPER EMPTY SENSOR
PEMPTY DGND
J11
3
Block Diagram 61. Paper Feed Electrical
611
6.3 Tension Roller Assembly 6.3.1 Removal and Disassembly

1. Open the Clamshell, remove the OPC and Developer Units, and any paper present in the Printer. 2. Remove the Front Plastic Paper Guide from the Transfer Charger Assembly by pressing down on its ends and sliding it to the left. This disengages the Locking Tabs and the Paper Guide can then be easily removed. See Detail 61.
Detail 61. Removing the Front Plastic Paper Guide 3. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the Printer by lifting the rear out first. See Figure 61. This helps it clear the Contacts for the High Voltage Power Supply and the Transfer Charger Frame. Disengage the Locking Tabs at the front of the Paper Guide from the Tension Roller Frame.
612
Detail 62
Step 3 Step 4
Step 4
6.4.1, Step 6
6.4.1, Step 5
6.4.1, Step 4
Figure 61 Removing the Lower Paper Guide
613
4. Remove 2 Screws at the rear of the Tension Roller Assembly, and remove it from the Printer. See Figure 61. 5. Remove 1 E-ring from the Drive Gear Shaft and remove the Tension Roller Gear. See Figure 62. Step 10 Step 11 Step 10
Step 7
Step 10 Step 11
Step 10
Step 5
Step 9 Step 6 Step 8
Figure 62. Removing the Tension Roller Gear 6. Remove 1 E-ring from the Transfer Gear Shaft and remove the Tension Roller Transfer Gear. 7. Remove 1 E-ring from the left end of the Tension Roller Shaft, then remove the Short Shaft Bushing. 8. Slide the Shaft to the right, remove the Spring Pin from the right end of the shaft, then remove the Tension Roller Gear from the Shaft. 9. Remove the Long Shaft Bushing, then slide the Shaft to either side so that the opposite end of the Shaft clears the Tension Roller Frame. 10. Remove the Teflon Pressure Roller Shaft by depressing the Retaining Spring and sliding either end of the Shaft off of the Spring. 11. Remove the 4 Teflon Pressure Rollers from the Shaft by removing 1 of 2 E-rings. NOTE: Upon installation, the Teflon Pressure Rollers must fit in the slots of the Tension Roller Frame.
614
NOTE:
Upon installation, check the dimension between the Shaft and the Tension Roller Frame (without the Tension Roller in place) with a caliper, as shown in Detail 63 below. If the dimensions are out of range, gently bend the spring to correct the dimensions.
Shaft
A, B = 0.492 0.01 inch (12.5 0.3 mm)
Detail 63. Checking Tension Roller Shaft Positioning 12. The Teflon Pressure Roller Retaining Spring can be removed from the Roller Frame, but the Spring should be removed only if the it is damaged and needs to be replaced. 13. Remove the Retaining Spring from the Tension Roller Frame by sliding a flat-blade screwdriver between the Spring and the Frame.
615

Reverse Steps 1 through 11 above. NOTE: When the Tension Roller Assembly is reinstalled in the printer, it must be positioned correctly using the locating pins. Install the left end of the Paper Guide first, then lock the tabs at the front into the slots on the Roller Frame. Ensure that the Tabs do not ride too low, under the Tension Roller Frame. See Detail 64.
Viewed from the Rear of the Printer
Detail 64. Reinstalling the Paper Guide
6.3.3 Adjustment
See Detail 63.
616
6.4 Drive Gear Assembly 6.4.1 Removal and Disassembly

1. Open the Clamshell, remove the OPC and Developer Units, and any paper present in the Printer. 2. Remove the Lamp Connector Cover by removing 1 Screw and sliding the cover toward the fuser. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Detail 65.
617
Step 2
Step 3
Detail 65. Removing Connectors
618
3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Detail 65. NOTE: Upon installation, the groove on the bottom of the Right Side Cover must straddle the top edge of the right side of the Tractor Frame. See Detail 62 in Figure 61 on page 613.
4. Open the Printer Front Cover, then remove the LCD Control Panel by removing 2 Screws. See Figure 61. 5. Remove the Right Side Cover by removing 3 Screws. See Figure 61 on page 613. 6. Remove 2 Screws from the Ozone Filter Case and remove it from the Printer. See Figure 61 on page 613. 7. Remove the Display Mounting Bracket by removing 2 Screws. See Figure 63. NOTE: The Cable Grounding Screw does not need to be removed.
8. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Remove the Frame Cover, and disconnect the Gear Assembly Stepper Motor Cable from the Motor. See Figure 63. NOTE: The Frame cannot be removed from the printer until the Fuser Base has been removed.
9. Remove 3 Screws from the Stepper Motor Board Frame (an 8 mm Screw holds the Board Frame to the Right Side Frame), but do not remove any additional cables from the Frame. This will allow the Frame to be moved in order to remove the Gear Assembly from the printer. See Figure 63. 10. Remove 4 Screws from the Gear Assembly Frame (a 10 mm Screw holds the Gear Assembly Frame to the Right Side Frame), then remove the Gear Assembly Frame from the printer. The Stepper Motor Board Frame must be moved in order to free the Gear Assembly from behind it. See Figure 63.
619
Step 8
Step 9
Step 10
Step 10
Step 7
Figure 63. Removing the Display Mounting Bracket
620
DISASSEMBLY
NOTE: The Stepper Motor can be removed from the Gear Assembly without removing the Gear Assembly from the Printer.
1. Remove 4 Screws, then remove the Stepper Motor from the Gear Assembly. See Figure 64. NOTE: When installing the Stepper Motor onto the Frame, the Cable Connector must face toward the rear of the printer. Step 8 Step 10 Step 6 Step 7
Step 5
Step 9
Step 4
Step 1
Figure 64. Stepper Motor Disassembly 2. Remove 1 E-ring, then remove the Tension Roller Drive Gear. 3. Remove 1 E-ring, then remove the Developer Drive Gear Assembly. This includes both bearings. NOTE: The Bearing Seal and both Ball Bearings can now be removed from the inside of the Gear.
621
4. Remove 1 E-ring and remove the Inner Transfer Gear. Then, remove 1 E-ring from each end of the Inner Transfer Gear Shaft. The Ball Bearing on each end of the Shaft can now be removed, and the Shaft can be slid clear of the Frame. NOTE: Do not remove the Spring Pin from the Inner Transfer Gear Shaft unless the Shaft is damaged and needs to be replaced.
5. Remove 1 Screw, then slide the Front Drive Gear and Shaft out of the Gear Assembly Frame. Remove 1 E-ring, then remove the Spacer and Gear from the shaft. NOTE: When reinstalling the Shaft, ensure that the Slot on the Shaft is aligned with the Slot in the Frame.
6. Remove 1 E-ring from the center of the Upper Gear Shaft to release the Upper Transfer Gear. 7. Remove 1 E-ring from the right end of the Upper Gear Shaft, then remove the right Bushing. 8. Align the Spring Pin of the Upper Gear Shaft with the Slot in the Frame and slide the Shaft to the left out of the Frame. NOTE: Remove the Spring Pin from the Shaft only if the Spring Pin or the left Bushing need to be replaced.
9. Remove the E-ring from the right end of the Lower Gear Shaft and remove the right Bushing. 10. Slide the Shaft to the left while aligning the Spring Pin with the Slot in the Frame. This will allow the Shaft to be slid free of the Frame. NOTE: Do not remove the Spring Pin from the Shaft unless it is absolutely necessary.

Reverse all of the Steps listed above.
6.4.3 Adjustment
No adjustment of the Drive Gear Assembly is necessary.
1. A fluttering noise is heard from the Upper Gear Shaft. a. Add grease (Molykote EM03L or similar) to the area between the Bushing and the Upper Gear Shaft. 2. A fluttering noise is heard from the OPC Drum Unit. a. Add grease (Molykote EM03L or similar) to the area between the Bushing and the Upper Gear Shaft. 3. The Developer Sleeve does not rotate.
622
a. The Inner Transfer Gear is broken. Replace the Inner Transfer Gear. 4. The Stepper Motor loses coordination with the OPC Drum Unit and the Developer Unit, even though the OPC Drum Unit and Developer Unit are new. a. Check the Stepper Motor wire harness. b. If the total page count is around 1,000 pages, check the Front Drive Gear.
6.5 Tractor Assembly 6.5.1 Removal and Disassembly

1. Remove the Fuser Heat Shield. See Figure 65.
623
Step 1
Detail 67
Step 5
Detail 66
Step 7
Step 4 Step 6
Step 2
Step 3
Figure 65. Tractor Removal
624
2. Remove the Lamp Connector Cover by removing 1 Screw and sliding the cover toward the fuser. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Figure 65. 3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Figure 65. NOTE: Upon installation, the groove on the bottom of the Right Side Cover must straddle the top edge of the right side of the Tractor Frame. See Detail 66 in Figure 65.
4. Remove the Tractor Encoder Cover by removing 1 Screw. NOTE: Upon installation, the groove on the bottom of the Encoder Cover must straddle the top edge of the left end of the Tractor Frame. See Detail 67 in Figure 65.
5. Remove the Tractor Paper Guide by removing 1 Screw from the center rear of the Tractor Frame. 6. Disconnect the Tractor Encoder Cable from the Connector on the Base Plate behind the Tractor by pressing on the release tab of the Connector. 7. Remove the Tractor by removing 3 Screws, then lifting the left end of the Tractor out first. This allows the the Encoder to clear the High Voltage Power Supply, and allows the Tractor room to move to the left so that the Tractor Stepper Motor can clear the Stepper Motor Board Frame. 8. Disconnect the Cable from the Tractor Stepper Motor and remove the Tractor from the Printer.
DISASSEMBLY
1. Remove 2 Screws from the Tractor Motor Frame and remove the Stepper Motor Assembly from the Tractor. See Figure 66. 2. Remove 2 Screws from the Stepper Motor Frame and remove the Stepper Motor from the Frame.
625
Front of Printer
Step 5

Step 1 Step 8 Step 7 Step 6

Step 2 Step 11 Step 8 Step 9
Step 3A
Step 4 Step 3B
Step 9
Rear of Printer
Step 3C
Figure 66. Tractor Disassembly
626
3. Encoder Board Removal: a. Remove the TOF Sensor from the Tractor Frame by gently pressing its retaining tabs. b. Remove 1 Screw from the Encoder Board and carefully slide it free of the Encoder Wheel so that neither the Wheel nor the Optical Sensors are damaged. The Tractor Cable is attached to the Encoder Board and must be removed with it. Carefully slide the Cable Connector free of the Tractor Frame. See Detail 68. NOTE: Be sure to note the Encoder Board position on the Tractor Frame before removing it. The Board can be slid back and forth to change its relation to the Encoder Wheel. This adjustment affects the position of the first line of print in relation to the page perforation. See Detail 68.
Front of Printer
Rear of Printer
Detail 68. Tractor Encoder Board c. The TOF Sensor cannot be removed through the cutout in the Tractor Frame as the Encoder Cable can. Therefore, the TOF Cable must be disconnected from the Encoder Board before either can be removed from the Tractor.
4. Remove the Encoder Wheel by removing 1 E-ring from the Tractor Drive Shaft and sliding the Wheel off of the Shaft. NOTE: Upon installation, the Timing Mark of each Tractor must face up. The Timing Dot on the Encoder Wheel must also face up and away from the Tractor Unit. The Flat Face of the Drive Shaft must face toward the rear of the printer. See Detail 69.
627

Note: The tractors are marked on the inside of each tractor, DL for left and DR for right.
Rear of Printer
Note: Align timing marks on both tractors to the timing dot on encoder wheel.
Timing dot on encoder wheel Flat face of drive shaft faces the rear of the printer

Detail 69. Tractor Encoder Board Positioning 5. Remove the Tractor Drive Gear from the Drive Shaft by removing 1 E-ring from the right end of the shaft, then sliding the Gear off of the Shaft.
628
TRACTOR ASSEMBLY REMOVAL

6. Loosen the Tractor Drive Shaft by removing 1 E-ring from the left end of the Shaft and sliding the Bushing off of the Shaft. NOTE: Do not remove the Spring Pin from the right end of the Shaft.
7. Slide the Shaft to the right so that the Bushing is clear of the Frame. 8. Loosen the Guide Shaft by removing 1 Screw from each end of the Shaft. 9. Loosen the Rear Guide Shaft by removing 1 E-ring and Bushing from each end of the Shaft. 10. The Tractor Assemblies and Shafts can now be removed from the Frame by lifting them out. It may be necessary to release the ends of the Guide Shaft from the Tractor Frame by gently pulling the ends of the Frame. NOTE: Upon assembly, the ends of the Guide Shaft must be aligned with the holes in the ends of the Tractor Frame.
11. The Centering Gear can be removed from the Tractor Frame by removing 1 E-ring. 12. Remove the Shafts from the Tractor Assemblies. NOTE: Upon assembly, the Drive Shaft must be installed so that the Timing Mark of each Tractor is facing up. This aligns both Tractors so that the Paper Pins are in the center of the Drive Shaft. The Drive Shaft must be installed so that the Flat Face for the Encoder Wheel is facing toward the rear of the printer. See Detail 69.
13. Remove the Centering Arm off of each Tractor by removing 2 Screws.

Reverse all of the Steps above as needed.
6.5.3 Adjustment
Adjusting the Tractor Encoder Board moves the first line of print on a page closer to or farther from the page break perforations. Perform this adjustment only if the original position of the Encoder Board was not noted during disassembly, or if the registration of the first line is unsatisfactory. NOTE: This adjustment will correct a misregistration of print when a customer is using preprinted forms. However, this adjustment will also affect all stock printed subsequently.
1. Remove 1 Screw, then remove the Tractor Encoder Cover. 2. Losen, but do not remove, 1 Screw on the Tractor Encoder Board. See Detail 610.
629
Front of Printer
Note: Loosen this screw, but do not remove it.
Rear of Printer
Detail 610. Adjusting the Tractor Encoder Board 3. Refer to Detail 610 and perform one of the following Steps: a. If the print is to be moved closer to the page break, slide the Tractor Encoder Board toward the front of the printer. b. If the print is to be moved farther from the page break, slide the Board toward the rear of the printer. 4. Tighten the Encoder Board Screw. 5. Run a print job and check the registration of the first print line. Repeat Steps 2, 3, and 4 if necessary. 6. Replace the Tractor Encoder Cover.
630
6.6 Lower Paper Guide and Paper Empty Sensor 6.6.1 Removal and Disassembly
1. Open the Clamshell. Remove any paper present in the printer. Remove the OPC Drum Unit, the Developer Unit, and the Waste Toner Container. 2. Remove the Front Plastic Paper Guide of the Transfer Charger Assembly by pressing down on the ends of the Guide and sliding it to the left. This disengages the Locking Tabs and the Guide can be removed easily. 3. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the printer by lifting the rear out first. See Figure 61. This helps the Guide clear the Transfer Charger Frame and the Contacts for the HVPS. Disengage the Locking Tabs at the front of the Guide from the Tension Roller Frame. 4. The Paper Empty Sensor can be removed from the Base Plate by releasing its retaining clips and removing 1 Screw from the Cable Clamp. NOTE: The Bottom Cover of the printer must be removed in order to disconnect the Paper Empty Sensor Cable from the Backplane Board.
5. Place the printer on a phone book or other similar item so that the Bottom Cover edges are not resting on the item. Press gently to release the 2 Locking Tabs on the right side of the Bottom Cover, then gently lower this side. See Detail 611. Slide the Bottom Cover slightly to the right to release the locking tabs on the left side, then lower the Bottom Cover away from the printer and over the phone book.
631
Detail 611. Bottom Cover Removal 6. Disconnect the Paper Empty Sensor Cable from Connector S11 on the Backplane Board. The Cable can now be routed through the Left Side Frame.

Reverse the 6 Steps above.
6.6.3 Adjustment
No adjustment is required.
632
Fuser Subsystem
71
7.1 Fuser Parts List 7.1.1 Fuser Assembly

Callout 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 33 35 36 37 38 39 Name Fuser Assembly, 115V Fuser Assembly, 230V Cover Assembly, Fuser Wiper Cover, Fuser Wiper Spring, Retaining, Fuser Wiper (2) Lower Fuser Assembly Frame, Fuser Pressure Roller Roller Assembly, Pressure Shaft, Pressure Roller Roller, Fuser Pressure Paper Peeler Assembly Paper Peeler Mylar Strip, Paper Peeler Spring, Extension, Paper Peeler E-Ring, 6mm I.D., Zinc (2) Upper Fuser Assembly, 115V Upper Fuser Assembly, 230V Frame Assembly, Heat Roller Frame, Heat Roller Shaft, Fuser Locating (4) Shaft, Pivot, Lower Assembly (2) Roller Assembly, Heat Roller, Fuser Heat Collar, Heat Roller (2) Gear, Drive, Heat Roller Thermistor Halogen Lamp, 115V Halogen Lamp, 230V Wire Harness, Halogen Lamp Bracket, Lamp Retaining, Right Bracket, Lamp Retaining, Left Thermal Breaker Assembly Thermal Breaker Bracket, Thermal Breaker Screw, PPH, MT, 3x4mm (2) Screw, PPH, CLFW, Zinc, 3x6mm (4) Snap Ring, External, 25mm I.D., Black Screw, PPH, CLFW, Zinc, 3x6mm (5) Cover, Heat Roller Brush Assembly, Fuser Discharge Guide, Paper Exit Brush, Fuser Discharge Cable Tie, Lamp Harness Vendor Part No. Printronix Part No. 202176501 704539012 202213501 704539013 202177551
202180501 202181001 202182501 202183001 202184001 202185501 202186001 202187001 202188001 071151010 202189501 202210501 202190551
202194501 202195001 202196001 202197001 202198551 202199551 202212551 202701551 202201001 202202001 202203501 202204001 202205001 030128304 030130306 073051048 030130306 202206001 202207501 202208001 202209551 201321001
72
7.1.1 Fuser Assembly (continued)

Callout 40 41 Name Caution Label, 115V Caution Label, 230V Fuser Wiper (Not part of this assembly) Vendor Part No. Printronix Part No. 202384001 202385001 202323501
73
1 Ref 16 Ref 28 1
3 1 15 Ref 17 1 35 1 2 Ref
4 2 33 9 36 Ref 37 1 18 4 38 1 41 1
22 2 20 Ref 21 1 11 1 12 1
31 1
32 2 19 2 30 1 27 1
10 Ref 7 Ref
24 1
29 Ref 23 1
8 1 9 1
34 1
13 1
25 1 26 1
(220 to 240V) or (100 to 120V)
14 2 40 1 6 1
(100 to 120V and 220 to 240V in common)
5 Ref
39 1
Fuser Assembly
74
7.1.2 Fuser Heat Shield Assembly

Callout 42 43 44 45 46 Name Heat Shield Assembly, Fuser Heat Shield, Fuser Caution Label, High Temp. Caution Label, Fuser Felt Seal, Dust Vendor Part No. Printronix Part No. 202211001 202386001 202387002 202388001
42 Ref
43 1 44 1 45 1
46 1
Fuser Heat Shield Assembly
75
7.1.3 Fuser Base Assembly

Callout 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 19 20 21 22 23 24 25 26 27 28 29 30 44 46 47 48 49 50 51 52 53 69 52 71 72 77 78 80 74 75 76 Name Fuser Base Assembly Frame Assembly, Fuser Base Frame, Fuser Base Pin, Fuser Clamp (2) Shaft, Exit Cover (2) Shaft, Tension Lever (2) Shaft, Exit Roller Lever (2) Shaft, Fuser Idler (2) Shaft, Input Drive Shaft, Idler, Exit Roller Paper Guide, Fuser Input Spring, Extension, Paper Guide (2) Paper Guide Assembly, Speed Control Paper Guide, Speed Control Shaft, Cam Follower, SCPG Spring, Extension, Speed Control Sensor, Paper Jam, Fuser (2) Fuser Sensor Board Fan, Fuser Cooling (2) Spring, Retaining, Fuser Fan (2) Stepper Motor, Fuser Frame, Fuser Stepper Motor Fuser Clutch Wire Harness, Fuser Clutch Gear, Transfer, Stepper Motor Gear, Drive, Heat Roller Gear, Drive, Exit Guide Gear, Drive, Cam E-Ring, 4mm I.D., Zinc (2) Ball Bearing, Cam Shaft (2) Shaft Assembly, Fuser Cam Shaft, Fuser Cam Cam, Paper Handling Cam, Speed Control Wheel, Fuser Position E-Ring, 6mm I.D., Zinc (5) Pin, Dowel, 2.5x12mm, SS (5) Cam, Pressure Roller (2) E-Ring, 6mm I.D., Zinc (2) Screw, PPH, MTF, IFM, 3x6mm, Zinc (7) Screw, PPH, CLFW, 4x10mm, Zinc (2) Clamp, Fuser, Mounted Tie Wrap, Fuser Fan Spring, Extension, PR Cam (2) Screw, PPH, CLFW, 3x6mm, Zinc (3) Wire Harness, Fuser Signal Clamp, Fuser Wire Harness, Nylon Vendor Part No. Printronix Part No. 202216501 704539082 202217551
202226001 202227001 202228551
202230001 202234551 202235551 202236551 202237001 202238551 202239001 202240551 202241551 202242001 202243001 202244001 202245001 071151006 202260551 202261501 202262001 202263001 202264001 202265001 071151010 081660212 202376001 071151010 030136306 030130410 202377001 202378001 202102001 030130306 202296551 202297001
76
12 2 11 1
13 Ref
14 1
71 4 74 1 6 2
1 Ref
15 1 47 Ref 46 2 52 1 53 5 3 1 80 2 48 1 2 Ref
7 2 5 2 19 1 74 1 8 1 10 1
69 1 52 1 49 1 22 2
16 1 28 1 50 1 52 3 77 1 78 1 51 1 25 1 69 1 52 1 30 1 4 2
8 1 29 1
9 1
44 2
27 1
71 2
A
21 2 71 1 20 1 76 1 75 1 74 1 19 1 26 1
72 2
52 1 24 1 23 1
Fuser Base Assembly
77
7.1.3 Fuser Base Assembly (continued)

Callout 17 18 31 32 33 34 35 36 37 38 39 40 41 42 43 44 44 45 54 44 55 56 57 58 59 60 61 62 63 64 73 65 44 59 60 61 62 63 64 73 66 57 67 68 70 Name Clamp, Fuser, Left Clamp, Fuser, Right Lever, Exit Roller, Left Spring, Torsion, Left Roller Lever Lever, Exit Roller, Right Spring, Torsion, Right Roller Lever Cover Assembly, Paper Exit Cover, Paper Exit Lever, Jam, Exit Cover Shaft, Exit Pressure Roller Roller, Exit Pressure (2) Shaft Assembly, Exit Roller Shaft, Exit Roller Bushing, Exit Roller (2) Gear, Drive, Exit Roller E-Ring, 4mm I.D., Zinc E-Ring, 4mm I.D., Zinc (4) Spring, Extension, Exit Cover (2) Lever Assembly, Pressure Cam, Left E-Ring, 4mm I.D., Zinc Lever Assembly, Pressure, Left Lever, Pressure, Left Bushing, Pressure Lever Lever, Cam Pressure, Left Cam Follower Shaft, Cam Follower Spacer, Cam Follower Spring, Compression, Pressure Screw, HC, 4x35mm, Zinc Nut, Hex, 4mm, Zinc Washer, Flat, 4mm I.D., Zinc Lever Assembly, Pressure Cam, Right E-Ring, 4mm I.D., Zinc Cam Follower Shaft, Cam Follower Spacer, Cam Follower Spring, Compression, Pressure Screw, HC, 4x35mm, Zinc Nut, Hex, 4mm, Zinc Washer, Flat, 4mm I.D., Zinc (2) Lever Assembly, Pressure, Right Bushing, Pressure Lever Lever, Pressure, Right Lever, Cam Pressure, Right E-Ring, 5mm I.D., Zinc (2) Vendor Part No. Printronix Part No. 202232001 202233001 202246001 202247001 202248001 202249001 202250501 202251001 202252001 202253001 202254001 202255501 704539102 202256552 202257001 202258001 071151006 071151006 202259001 202266501 071151006 202267551
202270001 202271001 202272001 202273001 202389001 031128435 061151004 050151006 202274501 071151006 202271001 202272001 202273001 202389001 031128335 061151004 050151006 202275551
202277001 071151008
78
35 Ref
36 1 45 2 39 2 44 2 37 1
17 1
32 1
31 1
38 1 44 1 41 1 40 Ref 42 2 44 1
44 1
56 1 73 1
63 1 58 1 54 Ref 70 1
43 1
57 1 62 1 64 1 60 1 59 1 61 1 44 1
55 Ref 70 1
73 2
33 1 34 1
63 1 68 1
57 1 62 1
18 1
64 1 44 1 61 1 59 1 60 1 67 1 65 Ref 66 Ref
Paper Exit Cover Assembly (Part of Fuser Base Assembly)
79

Cleaner Felt. This cleans the fuser roller of toner that gets deposited on the roller instead of the paper. It is impregnated with silicone which forms a film on the fuser roller that helps prevent toner from sticking. Fuser Sensor Wheel. This sensor wheel has blades that break the light beam in the optical sensors on the fuser sensor board. This helps set the fuser cam position. Fuser Exit Guide. This protects users from touching heated parts and keeps the paper from wrinkling. It also serves as a paper guide for paper that is exiting the printer. This guide is part of the Fuser Base Assembly. Fuser Roller. This Teflon-coated aluminum roller is heated and, in conjunction with the pressure roller, comes in contact with the paper. The heat causes the toner to be fused onto the paper. Fuser Roller Cam Shaft. This shaft has a cam on it that causes the Pressure Roller to move and press the paper between the Fuser Roller and the Pressure Roller. Fuser Frame Assembly. This assembly holds the Fuser Rollers and Thermistor. It is removable for easy replacement. Paper Peeler. This prevents paper from curling around the Fuser Roller by peeling the paper off of the Fuser Roller. Pressure Roller. This is a rubber roller that comes in contact with the Fuser Roller during fusing. Static Brush. This brush removes the static charge from the paper as it exits the printer. Engagement Lever Cam. This cam is located in the left center of the Fuser Roller Cam Shaft. It moves the Engagement Lever, thus causing the Transfer Charger to move away from the paper when printing stops.
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7.2.2 Electrical
The electrical portion of the fuser has four main sections: S A halogen lamp for heating the Fuser. In series with the lamp is a Thermal Breaker to switch off power to the lamp if there is a problem with the heater control circuit. S A sensor board mounted to the Fuser Base Assembly. This sensor board has six optical sensors associated with it that monitor the Fuser when up, the Fuser when down, the Paper Handling Lever position, the Speed Control Lever position, and entry and exit paper jam sensors. S A thermistor sensor mounted to the frame of the Fuser Assembly that monitors the heat of the Fuser Roller. S Two fans mounted in the Fuser Frame that cool the ends of the Pressure Roller. Details about specific Units: Fuser Fans. These fans cool the outer edges of the Pressure Roller, which is especially useful during narrow-forms printing. Fuser Cam Clutch. This is a clutch that causes the Fuser Roller Cam Shaft to rotate in order to open or close the Fuser and move the Paper Handling Lever and the Speed Control Lever. Fuser Sensor Board. This board has 4 optical sensors: 2 for positioning the Speed Control Paper Guide, and 2 for positioning the Fuser Roller Cam. The Fuser Sensor Board is the interface between the Engine Controller and the Fuser. Fuser Stepper Motor. This motor drives the Fuser forward. Additionally, if the Fuser Cam Clutch is on, this motor drives the Fuser Roller Cam Shaft. Heater Lamp. The Heater Lamp is located in the center of the Fuser Roller and heats the Fuser Roller. Thermistor. This is a temperature sensor that is in contact with the Fuser Roller. It is used in conjunction with the heater circuitry to keep the Fuser Roller at the correct temperature. Thermal breaker. This is a heat-activated switch in series with the lamp heater circuitry. It functions as a power shutoff when it reaches 155 C.
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FUSER UNIT
THERMISTOR Thermal Breaker Halogen Lamp
*
6 1
CNS1 220 110 202576 S801
LVPS
3 2 CN4 1

CN8 1 2 3 CN6 1 2 1 +24VB CN5 6 8 +24VB A B /A /B BGND CN1 1 BGND BGND +24 +24 +24 GND +5 202200 S802 TMRPW TMRSG
202292 S211
* 120V to Pin 2
240V to Pin 3
202298 S208
PRFAN1 PRFAN2
202241 S212
202238 D112
J2 202234 D162 J3
PR CLUTCH
FUSER STEPPER MOTOR (M3)
+5 /PRPOS 1 /PRINIT /SCPUP 202296 S210
BACKPLANE BOARD
J5
JAM SENSOR
J4
J1
/SCPDN PJAM EJAM /PRFAN
FUSER BASE UNIT

EXIT JAM SENSOR 202234 D162 10 J5
DGND +24
10
Block Diagram 71. Fuser Electrical
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7.2.3 Fuser Control Modes

Fusing Mode. In Fusing Mode, the Engine Controller keeps the Fuser at the fusing temperature. Fusing temperature is set in 5 C increments from 165 C to 185 C. Proper fusing temperature depends on the media in use. When the Data Controller sends a print command to the Engine Controller, the Engine Controller activates Fusing Mode. This mode is also used during engine self-test. Standby Mode. In Standby Mode, the Engine Controller keeps the Fuser at standby temperature, approximately 165 C. Standby Mode keeps the inside of the engine from getting too hot; it also reduces power consumption. When the Data Controller sends a print command to the Engine Controller, the Engine Controller switches the Fuser from Standby Mode to Fusing Mode. If the engine is idle for approximately 180 seconds in the Fusing Mode, the Engine Controller automatically switches the Fuser to Standby Mode. The Data Controller can switch the mode from Idle to Standby by using the Standby Mode Request Command. Idle Mode. In Idle Mode, the Engine Controller lets the Fuser cool to near ambient temperature by turning off the power to the Fuser. When the Fuser receives a print command, the Engine Controller switches the Fuser from Idle Mode to Fusing Mode. The Data Controller can request Idle Mode by issuing an Idle Mode Request Command. Note that the Engine Controller does not automatically change the Fuser to this mode.
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7.3 Fuser Assembly 7.3.1 Removal and Disassembly

1. Open the Clamshell and remove the OPC and Developer Units, as well as any paper present in the Printer. 2. Remove the Fuser Heat Shield, then remove the Lamp Connector Cover by removing 1 Screw. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Figure 71.
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7.3.1, Step 5 7.4.1, Step 7
7.3.1, Step 4 7.4.1, Step 6

Depress white retaining levers to release fuser roller assembly from fuser base
7.3.1, 7.4.1, Step 2
7.4.1, Step 8
J1 Connector
7.4.1, Step 12
Detail 73
7.4.1, Step 4
7.4.1, Step 3
7.4.1, Step 11 7.4.1, Step 10
7.4.1, Step 9
Figure 71. Fuser Assembly Removal
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3. Open the Paper Exit Cover on the back side of the Fuser Base so that it is not in contact with the Fuser Assembly. 4. Depress the Fuser Retaining Lever on each side of the Fuser Base so that the Fuser Assembly is free to move. 5. Lift the Fuser Assembly free of the Fuser Base, then remove it from the Printer.
DISASSEMBLY
6. Open, then remove, the Fuser Wiper Cover by gently pressing in on its retaining tabs. Remove the Fuser Wiper. See Detail 71. 7. Remove the Upper Heat Shield by removing 1 Screw, then releasing the tabs in the corners of the Shield using a small flat-blade screwdriver. See Detail 71. Do this by gently pulling the sides of the Shield outward, releasing the Front Tabs, then sliding the Shield backwards to release the Rear Tabs. 8. Remove 2 Screws from the bottom of the Heat Roller Frame and remove the Jam Protector. See Detail 71.
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Step 6 Step 7
Fuser Roller Cover locking tab locations
Step 7
Step 8
Pivot is on inside of Frame
Step 8
Detail 71. Removing the Upper Heat Shield
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9. Remove 1 Spring from the right rear side of the Fuser Pressure Roller Frame. See Figure 72.
Step 15
Step 10 Step 13
Step 18
Step 16 Step 10
Step 12 Step 9 Step 18 Step 19 Step 14
OR
(220 to 240V only)
Step 11
Step 12 (100 to 120V and 220 to 240V in common) (100 to 120V only)
Figure 72. Fuser Assembly Disassembly
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10. Remove 1 Screw from each side of the Roller Frame, then remove the Fuser Pressure Roller and its Frame by disengaging the Pivot on each side of the Heat Roller Frame. See Figure 72. 11. Lift the Fuser Pressure Roller out of its Frame. NOTE: Do the next Step (removal of the Fuser Pressure Roller Shaft from the Roller) only if absolutely necessary.
12. Remove 1 E-ring from the each end of the Pressure Roller Shaft, then slide the Shaft from the Roller. This will allow you to remove the Paper Peeler from the Roller, and Ball Bearing from each end of the Roller. See Figure 72. NOTE: The Shaft has a very tight fit in the Ball Bearings and should be removed only if the Bearings are seized.
13. Remove the Thermistor by removing 1 Screw. See Figure 72. 14. Disconnect both Lamp Leads from the Thermal Breaker, then the Thermal Breaker and Bracket can be removed from the Fuser Roller Frame by removing 1 Screw. The Thermal Breaker can be removed from its Mounting Bracket by removing 2 Screws. See Figure 72 and Detail 72. NOTE: If the Thermal Breaker Mounting Bracket is removed from the Heat Roller Frame, then the height of the Thermal Breaker surface from the Heat Roller must be set properly, as described in the Adjustment section that begins on page 721. If the Thermal Breaker Mounting Bracket is not removed from the Heat Roller frame, but the leads from the lamp to the Thermal Breaker are disconnected and reconnected, then the height of the Thermal Breaker surface over the roller must be measured and adjusted if needed.
Detail 72. Thermal Breaker and Mounting Bracket
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15. Remove 1 Screw from the Left Lamp Retaining Bracket and remove the Bracket from the Heat Roller Frame. See Figure 72. 16. Remove 1 Screw from the Right Lamp Retaining Bracket and remove the Bracket from the Heat Roller Frame. See Figure 72. 17. Remove the Lamp Assembly from the center of the Heat Roller by sliding it to the right. NOTE: Ensure that you do not touch the lamp as fingerprints will cause it to fail. Clean it with a cloth and isopropyl alcohol before reinstalling it.
18. Remove the Heat Roller from the Heat Roller Frame by lifting the Retaining Collars free of the Frame. Slide the Retaining Collar on the left end of the Roller off of the Roller. See Figure 72. 19. Remove the External Snap Ring from the right end of the Heat Roller, then slide the Drive Gear and Retaining Collar off of the right side of the Heat Roller. See Figure 72.

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7.3.3 Adjustment Thermal Breaker

NOTE: The height of the Thermal Breaker from the Fuser Roller must be adjusted every time the Thermal Breaker is removed from the Fuser. If the Thermal Breaker is too close to the Fuser Roller, the Breaker will trip at too low a temperature. If the Breaker is too far from the Roller, the Breaker will trip at too high a temperature. See Detail 72.
1. Place the Thermal Breaker Bracket into place so that the left side is flush against the locating notches. Put the Bracket Screw in place so that it holds the Bracket loosely in place. 2. Hold the Fuser Roller up into the top of the Frame to simulate a closed Fuser. Using a Feeler Gauge, adjust the gap between the Thermal Breaker and the Fuser Roller by sliding the Bracket so that the Thermal Breaker just touches the Gauge. This gap must be between 0.62 mm and 0.88 mm, with a nominal setting of 0.75 0.13 mm. 3. With the Bracket set so that the Feeler Gauge is not bound by the Thermal Breaker, tighten the Bracket Retaining Screw to 6.9 inch-pounds (8 "1 kg-cm) of torque.
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7.4 Fuser Base 7.4.1 Removal and Disassembly

1. Open the Clamshell and remove the OPC and Developer Units, as well as any paper present in the Printer. See Figure 71. 2. Remove the Fuser Heat Shield, then remove the Lamp Connector Cover by removing 1 Screw. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Figure 71. 3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Figure 71. NOTE: Upon installation, the groove on the bottom of the Right Inside Cover should straddle the top edge of the right side of the Tractor Frame. See Detail 73 in Figure 71.
4. Remove the Tractor Paper Guide by removing 1 Screw from the center rear of the Tractor Frame. 5. Open the Paper Exit Guide of the Fuser Base so that it is not in contact with the Fuser Roller Assembly. 6. Depress the Fuser Assembly Retaining Lever on each side of the Printer so that the Fuser Assembly is free to move. 7. Lift the Fuser Assembly free of the Fuser Base, then remove it from the Printer. 8. Disconnect the Fuser Sensor Board by removing the Cable at Connector J1. 9. Open the Printer Front Cover, then remove the LCD Control Panel by removing 2 Screws. 10. Remove the Right Side Cover by removing 3 Screws. 11. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Remove the Frame Cover, and disconnect 2 Cables from Connectors CN5 and CN6 on the Stepper Motor Board. 12. Remove 2 Screws from the rear of the Fuser Base and remove it from the printer.
DISASSEMBLY
13. Remove the Paper Exit Guide by removing 2 Springs, then lifting the Guide off of the Shaft on the Fuser Base Frame. See Figures 73 and 74.
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Step 13 Step 13A Step 13B Step 13C Step 14 Step 13E Step 13
Step 35 Step 33
Step 13B Step 13D
Step 31 Step 33
Step 36
Step 32
Step 16
Step 34
Figure 73. Paper Exit Cover Disassembly
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Step 26
Step 26 Step 22
A
Step 24 Step 25 Step 25A
Step 28
Step 31 Step 22 Step 18 Step 19 Step 25B Step 30 Step 25C Step 25D Step 25A Step 30 Step 29 Step 23 Step 17
Step 20 Step 21 Step 28 Step 27 Figure 74. Fuser Base Disassembly Step 15
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a. Remove the Upper Exit Guide Shaft by removing 1 E-ring from the left end of the Shaft and sliding the Shaft to the right. The Shaft must be slid free of the 2 Teflon Rollers and the Frame. b. Disengage the Locking Tab of both Lower Exit Guide Shaft Bushings from the Exit Guide Frame. Rotate both Bushings so that the flat portion of each Bushing is aligned with the flat portion of the Frame. Lift the Shaft free from the Frame. c. Remove the E-ring from the left end of the Shaft and remove the Bushing.
d. Gently release the tabs of the Lower Shaft Drive Gear and remove it from the Shaft. Slide the right Bushing off of the Shaft. CAUTION: The Locking Tabs of the Gear can be easily broken and must be gently pried free of the Shaft.
e. Remove the Exit Guide Jam Lever from the Frame by gently spreading the Arms of the Frame to release the Tabs on the Jam Lever. 14. Only if necessary, remove the left side Fuser Roller Locking Lever from the Fuser Base Frame. If the Locking Lever must be removed, do not reuse it. Replace it with a new Locking Lever. 15. Remove 2 Screws, then remove the Stepper Motor and Frame from the Fuser Base Frame. The Stepper Motor can be removed from its Frame by removing 2 Screws. See Figure 74. NOTE: When installing the Stepper Motor and Frame ensure that the alignment prongs of the Fuser Clutch are engaged around the tab of the Stepper Motor Frame. The Cable Connector for the Stepper Motor must face the front of the Printer. See Detail 74.
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Clutch cable positioned toward front of printer
Front of printer
Detail 74. Fuser Stepper Motor Clutch Positioning 16. Only if necessary, remove the right side Fuser Roller Locking Lever from the Fuser Base Frame. If the Locking Lever must be removed, do not reuse it. Replace it with a new Locking Lever. 17. Remove the Fuser Transfer Gear from the Fuser Base Frame. 18. Remove 1 E-ring, then remove the Rear Inner Transfer Gear. 19. Remove 1 E-ring, then remove the Exit Guide Drive Gear. 20. Remove 1 E-ring from the Shaft for the Fuser Clutch, then remove the Fuser Clutch from the Shaft. NOTE: Do not disassemble the Fuser Clutch. Keep all Fuser Clutch parts together as one Assembly. Do not remove the cable from the Clutch Assembly unless absolutely necessary.
21. The Front Inner Transfer Gear can be removed after the Clutch Assembly has been removed. 22. Remove the Spring from the center of the Speed Control Paper Guide, then remove 1 Screw from each end of the Guide and remove it from the Fuser Base. 23. With the Fuser Clutch removed, slide the right Fuser Cam Ball Bearing off of the Shaft.
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24. Remove 1 E-ring from the left end of the Fuser Cam Shaft, then remove the left side Ball Bearing. 25. Lift the left end of the Fuser Cam Shaft free of the Fuser Base Frame, then slide the Shaft to the left to free the right end from the Base Frame. This will free the Shaft from the right Pressure Roller Cam. a. Slide the Pressure Roller Cam from each end of the Cam Shaft and remove the Dowel Pin. Then remove the E-ring for the Fuser Cam from each end of the Cam Shaft. b. Remove the E-ring for the left Pressure Roller Cam, then the E-ring for the Paper Handling Cam, and slide the Paper Handling Cam off of the Cam Shaft. Remove the Paper Handling Cam Dowel Pin from the Shaft. c. Remove the E-ring for the Speed Control Cam, and slide the Cam to the left and off of the Shaft. Remove the Speed Control Cam Dowel Pin from the Cam Shaft.
d. Remove the E-ring for the Fuser Position Wheel and slide the Wheel to the left and off of the Shaft. Remove the Position Wheel Dowel Pin from the Cam Shaft. NOTE: When assembling the Fuser Cam Shaft, all of the alignment holes in the Cams must be aligned to the bottom of the Shaft. The curved surface of the Fuser Cams must face toward the front of the printer (except for the Paper Handling Cam). The slot in the right side of the Position Wheel must be facing up, away from the alignment holes. See Detail 75. Upon Installation, the right Pressure Roller Cam must be positioned in the Fuser Base Frame, then the right end of the Cam Shaft must be slid through the Cam and the Base Frame.
NOTE:
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Detail 75. Cam Positioning 26. Remove the Rear Paper Lift Spring from both ends of the Lift, then remove 1 Screw from each end of the Lift. Remove the Rear Paper Lift from the Fuser Base Frame. 27. Disconnect the Cable from the Fuser Jam Sensor, then remove the Sensor by carefully releasing the retaining tabs from the Fuser Base Frame. 28. Disconnect the Cable from the Exit Guide Jam Sensor, then remove the Sensor by gently releasing the Retaining Tabs from the Fuser Base Frame.
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29. Disconnect the Cables for the Fuser Cooling Fans from the Fuser Sensor Board, then remove 1 Screw to remove the Sensor Board. CAUTION: Use care when removing the Exit Guide Jam Sensor Cable from the Fuser Base Frame. The Cable can be damaged easily by the edges of the Frame.
30. Remove the Retaining Spring from each Fuser Cooling Fan, then remove the Fans. 31. Remove the Return Spring on the Left Pressure Cam Lever Assembly, then remove 1 E-ring and remove the Assembly from the Fuser Base Frame. NOTE: Make sure to note the direction of the Return Spring.
32. Remove 1 E-ring and remove the Cam Follower and Shaft from the Left Cam Pressure Lever. NOTE: Make sure to note the position of the Spacer on the Shaft.
33. Remove 1 Screw, 1 Spacer, and 1 Nut from the Left Pressure Spring, then separate the Cam Pressure and Pressure Levers from one another. Do not remove the Bushing from the Lift Arm. 34. Repeat Steps 31 through 33 for the Right Pressure Cam Lever Assembly. NOTE: The right Tension Arm Assembly uses 2 Spacers.
35. Remove 1 E-ring, then remove the Left Exit Roller Lever and Spring. 36. Remove 1 E-ring, then remove the Right Exit Roller Lever and Spring.
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7.4.3 Adjustment Fuser Thermistor

There are no adjustments to the Fuser Thermistor. You can, however, check the voltage across it. Use a digital voltmeter for this measurement. Under normal conditions, the following voltages will be present across the Fuser Thermistor: Approx. Voltage Across Thermistor Fuser Temperature Approx. 20 C (ambient temperature) 160 C (standby mode) 185 C (running temperature) 4.7 VDC 0.8 VDC 0.5 VDC
If your measurement shows an open condition ( , 5.0 volts DC across the Thermistor), refer to the troubleshooting section on page 731 for assistance.
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To properly troubleshoot the fuser section, mentally separate the assembly into four functional sections: S Heater and heat safety section (thermal breaker) S Temperature control section (thermistor) S Paper positioning section S Fuser section Troubleshooting procedures for each of these four functional sections follow.
Fuser Heater and Thermal Breaker

The fuser heater is a quartz halogen lamp that has a rating of 1000 watts. The heater safety device is a one-shot normally-closed thermal breaker that has a trip point of 155 C. This thermal breaker ensures that the printer (not necessarily the fuser) is not damaged if the temperature control does not function correctly. If the thermal breaker senses an over-temperature condition, it will open and remove power from the heater lamp. During initial power up and during any warmup period, there is a signal generated in the engine controller called HEAT. This signal is generated by monitoring the TMRSG line returning from the thermistor. When the controller decides that it is time to heat the fuser, it generates a low on the HEAT line. This signal leaves the controller via J88 on the Backplane Board. This TTL signal controls a solid-state relay (TRIAC) in the Low Voltage Power Supply which gates 115 volts out of the supply on pins CN41 and CN42. (If the Low Voltage Power Supply is set for 230 volts, it gates 230 volts out CN41 and CN43.) This voltage, in turn, goes to the lamp and thermal breaker, which are wired in series. If the Fuser Lamp Does Not Heat: 1. Allow the printer cool down to ambient temperature and unplug the printer from the power outlet. 2. Open the printer and remove the cover that fits around the drive gear assembly. Locate S211 (CNS1), the output from the Low Voltage Power Supply to the fuser lamp, and unplug the fuser lamp connector from it. See Figure 75.
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Lamp
B A
Thermal Breaker
Thermistor
B
D
(100 to 120V and 220 to 240V in common)
(100 to 120V) or (220 to 240V) S211 (CNS1)
Figure 75. Fuser Lamp, Thermal Breaker, and Thermistor Detail
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3. Measure the resistance across the terminals on the lamp side of the cable (C and D). It should measure less than 2 (less than 6 for 220 VAC units). If not, remove the heat shield cover and measure across the thermal breaker (A and B). It should measure near 0 . If the thermal breaker measures near 0 , then check the lamp. Measuring across B and D should result in less than 2 (less than 6 for 220 VAC units). If not, then replace the lamp. CAUTION: Use extreme care in handling both the old and new lamps, as the lamps are extremely fragile. Also, avoid getting fingerprints on the new lamp as this will shorten its life. If you get fingerprints on the lamp, wipe the lamp with a soft cloth soaked with alcohol. Allow the lamp to dry completely before powering on the printer.
If the thermal breaker is open ( CAUTION:
), replace it.
If you replace the thermal breaker, you must check the operation of the heat sensing circuit (thermistor and Low Voltage Power Supply). Otherwise, you might be merely correcting symptoms caused by a more serious problem, rather than correcting the more serious problem.
4. If both the lamp and thermal breaker check OK, reinstall the heat shield cover. Then defeat the cover interlock switch, the paper empty switch, and the top-of-form switch. Connect the printer power cord to the power outlet, turn on the printer, and check the voltage at S211 (CNS1). WARNING: When you defeat the cover interlock switch, there is 115 VAC at various parts of the power supply and high voltage at other contactsso BE VERY CAREFUL.
Be sure that all cables and test leads are out of the way of any moving parts (gear train, tractor, etc.). At this point, 115 VAC should not be present at the output of S211 (CNS1). If 115 VAC is present, you should suspect a faulty thermal breaker, one that is intermittent. It is unlikely that the lamp is faulty, since lamp faults usually are visible (broken tungsten wire or cracked glass envelope). 5. If 115 VAC is not present at S211 (CNS1), then turn off the printer and disconnect its power cord. Remove the bottom cover from the printer. Disconnect the 2 connectors CN1 and CN2 on the Low Voltage Power Supply. See Figure 77 on page 734. Check the main power fuse F1 (6.3 amp, 250 VAC), then check fuse F3 (15 amp, 125 VAC). This is the fuse that protects the output. If this fuse is good, check the input of the power supply at CN216 (the HEAT signal). To check this, you will have to very carefully replace the power cord to the printer. You will also need to defeat the cover interlock switches as per Step 4 above. WARNING: When you replace the power cord, there is 115 VAC at various parts of the power supply so BE VERY CAREFUL.
Using either a voltmeter or a logic probe, monitor pin 16 of CN2. When you turn the power back on, the printer should pause for a few seconds and then try to heat the fuser. At this point, the HEAT signal should go from +5.0 VDC to +0.7 VDC. If the voltage changes from high to low and you still do not have 115 VAC at CN4, then replace the Low Voltage Power Supply.
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However, if CN216 does not change from high to low, then suspect either the wiring harness or the engine controller. To check the harness, remove the power cable and all consumable items from the printer. Then remove the bottom cover from the printer per the cover removal section. Check continuity between the Low Voltage Power Supply CN216 and the engine controller. If the harness checks good, then replace the engine controller.
Figure 76. Fuser Heat Shield
CN5 CN6 CN4 F3 F2
RV1
CN3 RV4 CN2
CN1 F1
RV2
Figure 77. Inside View of Low Voltage Power Supply
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Temperature Control Section (Thermistor Troubleshooting)

To detect the temperature of the fuser roller, the engine controller sends an analog signal, TMRPWR, to the Stepper Motors Controller Board. This signal exits the board at connector CN81 and is passed through cabling to the thermistor. This, in turn, is fed through the thermistor and back to the Stepper Motors Controller Board at CN82 as TMRSG. The heat control thermistor is mounted so that it makes contact with the fuser heat roller at about the center of the fuser roller. The thermistor has a negative thermal coefficient; when the fuser temperature rises, the resistance of the thermistor goes down, and vice-versa. Normal operating boundaries of the fuser are in the range of 182 C to 188 C. During normal operation, when the temperature reaches the lower trip point of about 185 C, the engine controller turns on the HEAT signal. Then the lamp heats the fuser roller until the temperature reaches about 186 Chowever, this temperature might be different, depending on the setting of the temperature on the Control Panel. At this point, the engine controller shuts off the HEAT signal. There will be some thermal lag, so the temperature might exceed this set point by 5 C or more. To measure the temperature, use a temperature probe. Access to the fuser is limited, so obtain the smallest possible diameter surface-reading probe. Thermistor Malfunction Symptoms There are several conditions where you might suspect that the heat sensing control circuit is malfunctioning: S If a THRMISTR FAIL or HEATER FAIL error message is displayed on the front panel. S If the thermal breaker needs replacement (see previous section). S If the printed characters are not fusing to the paper correctly. 1. A THRMISTR FAIL or HEATER FAIL error message signifies one of the following conditions: a. The thermistor circuit has opened up or shorted, or the fuser never reaches the correct temperature. b. Units other than the thermistor circuit could be at fault. The thermistor condition can be checked by removing the fuser heat shield cover. Unplug the thermistor lead. Measure the resistance of the thermistor. At normal ambient temperature (20 C), the reading should be from 150 k to 200 k. If you find an open circuit, replace the thermistor (see fuser removal and replacement). CAUTION: Be sure to check the heater lamp and thermal breaker according to the first portion of this section before you continue. An open condition of either the lamp or the thermal breaker will cause the thermistor to appear defective (by not heating up the fuser roll).
2. If you found the thermal breaker to be open during testing, thoroughly check the thermistor section using Step 1 above and Step 3 below. 3. If the print on the fused paper feels excessively raised, then there might be an undertemperature condition at the fuser. First, confirm that the fuser temperature set via the control panel matches the type of paper being used.
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Then, to measure the fuser temperature, use a temperature probe. Let the printer cool to ambient temperature, then open the printer cover and defeat the cover interlock switch. WARNING: When you defeat the cover interlock switch, there is 115 VAC at various parts of the power supply and high voltage at other contactsso BE VERY CAREFUL.
Defeat the following sensors: S OPC drum switch (if the OPC drum is not installed) S Paper empty at the front of the printer S Top of form sensor at the fuser assembly Flip the exit paper guide out and away from the printer. Turn on the printer. Be extremely careful of moving parts. In about 120 seconds, the fuser roller should come up to proper temperature. The temperature of the fuser roller should be about 185 C (change it, if necessary, using the control panel) and the temperature range about 5 C. If not, check the position of the thermistor. It should be mounted in contact with, and parallel to, the fuser roller. If the position of the thermistor is correct, you should replace either the thermistor or the engine controller, or clean excess toner off of the thermistor.
Paper Positioning Section

The paper positioning section consists of a clutch and a stepping motor that has reduction gears attached to the driving end to increase the torque of the motor. Without the gears, a much larger motor would be required. Troubleshooting the fuser drive motor is fairly straightforward. The motor rotates and the clutch is on until the pressure roller is in its initial position during initialization of the printer (if the pressure roller is not in its initial position) and after it acts according to print requests. If there is data to be printed, the motor and the clutch are activated and the fuser is cantilevered against the pressure roller. During printing, only the motor is activated. After the data stream stops and the print cycle is finished, the motor and clutch are activated, which releases the fuser from the pressure roller. When the FORM FEED button is pressed, only the motor cycles. When the motor is in position, it is locked with a detent torque.
Fuser Fan Troubleshooting

The fuser fans cool the ends of the pressure roller. During narrow forms printing, the paper (or label) stock dissipates heat in the center of the pressure roller. The areas of the roller without paper expand and cause the stock to move slower through the fuser. The fuser fans also cool the end of the heat roller during narrow forms printing. If the heat roller stops, the thermal breaker (thermostat) senses an overtemperature condition. The breaker will then open, which removes power to the heater lamp. The fans are powered by the switched 24 volts supplied from the engine controller board connector J5, to the fuser sensor board connector J1. Connector J1 sends the 24 volts directly to the fans through connectors J2 and J3. The fuser fans activate only when the heat roller temperature is at fusing temperature, as set from the control panel. Check that the fans are activating when the heat roller is at fusing temperature. Remove the fuser heat shield and fuser front paper guide. Watch the fans during the printer power up sequence to verify that they are working. If they are not working, check for 24 volts on the fuser sensor board, connectors J2 and J3. If 24 volts is not present at these connectors, check for a loose connector at J1.
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Power Supplies
81
8.1 Power Supplies Parts Lists 8.1.1 Low Voltage Power Supply
Callout 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Name Low Voltage Power Supply (LVPS) Tie Wrap, Wire Harness, Lamp Power Bracket, Lamp Cable Wire Harness, Lamp Power Wire Harness, Thermistor Wire Harness, Lamp Fuse, 250V, T6.3AH (2: F1 and F2) Fuse, 125V, 15A (F3) Screw, PPH, CLFW, 3x10mm, Zinc Cover, Top, LVPS Switch, Power, LVPS Screw, PPH, CSW, 3x6mm, Chrome (2) Power Cord (see note below) Wire Harness, Controller Power, 5V Vendor Part No. Printronix Part No. 202127552 704539029 202175001 202215001 202292503 202200551 202576551 200465019 201938014 030130306 202577001 202578551 030235306 202375551
NOTE:
Use a power cord that is appropriate for the voltage of the printer and the country in use. Cords include the following plugs for the indicated areas:
Continental Europe
United Kingdom
Australia and New Zealand
U.S.A. and Canada
NOTE:
For Switzerland, use an SEV-approved plug.
Power Plugs
82
5 1 6 1
To Fuser
4 Ref 2 1
9 1
12 2
A
1 Ref 10 1 11 1
CN1 CN2
7 2 8 1 3 1
9 1
CN6 F3
CN5
CN4 F2
RV1
CN3 RV4 CN2
F1 CN1 RV2
83
8.1.2 High Voltage Power Supply

Callout 1 2 Name High Voltage Power Supply Screw, PPH, CLFW, M3x10, Zinc (2) Vendor Part No. Printronix Part No. 202126551001 704539033 030130310
84
2 2
1 1
85

There are two power supplies in the printer: The Low Voltage Power Supply (LVPS) and the High Voltage Power Supply (HVPS).
8.2.2 Electrical
The LVPS provides +5 VDC, +12 VDC, +24 VDC, and 12 VDC for operation of motors, logic boards, floppy disk drives, and the control panel. The HVPS provides 400 mA for the charge corona, 720 VDC for the charge grid, +4,600 VDC for the transfer corona, and 550 VDC for the developer. Note that the fuser lamp is powered directly from the AC supply (115 VAC or 230 VAC) and not from either of the internal power supplies. However, on/off control of the fuser lamp is performed at the LVPS.
86
FUSER UNIT
*
6 1
AC POWER INLET CNS1 CN3 220 110 202576 S801 202298 S208 3 2 CN4 1 + 1 COOLING FAN 2
TMRPW TMRSG
LOW VOLTAGE POWER SUPPLY

CN2 CN1 +5 1 +5 +5 +5 8 J7 1 J15 4 (NOT USED) 8 DGND DGND DGND DGND DGND DGND DGND DGND 202375 S207
202292 S211
* 120V to Pin 2
240V to Pin 3
(TO ENGINE CONTROLLER BOARD) +5 /PRPOS 1 /PRINIT /SCPUP /SCPDN PJAM EJAM DGND +24 /PRFAN J5 1 2 10 3 4 5 6 7 8 J1
(TO DATA CONTROLLER BOARD) J2
AGND AGND PWROFF /HEAT
+24 BGND +12 12
+5 1 DGND +24 +24 +24 5 BGND BGND BGND +24 BGND 10 +12 12 AGND AGND PWROFF /HEAT 16
10
J8
BACKPLANE BOARD
J3 (TO LCD CONTROL PANEL) RSVD Vss Vdd RS R/W E DB0 DB1 9 10 11 12 13 14 15 16 DB2 DB3 DB4 DB5 DB6 DB7 /SWRST /SWONL J3 24 1 17 /SWFF 18 /SWMENU 19 /SWSTOR 20 /SWUP 21 /SWDWN 22 /LRDY 23 /LONLN 24 /LDATA J4 +12 1 /QLED +24 BGND /PMON 5 /PMRDY +5 DGND /BD +5 10 DGND /LDON /LVIDEO LVR 14
+5 +5 +5 +5
1 J14 4 (NOT USED)
COPEN 1 /OPC /NEWOPC TMRSG TMRPWR /OZNFAN /PRCL PHA1 PHB1 /PHA1 /PHB1 PDWN1 PHA2 PHB2 /PHA2 /PHB2 PDWN2 PHA3 PHB3 /PHA3 /PHB3 PDWN3 +5VL +24VB +5 PFS8 PFS6 /PTOP DGND
201153 S203 J6
LCD CONTROL PANEL
202294 S204 TO LSU
1 J10
+24VB /CHARGE /DEVELOPER /TRANSFER BGND 202291 S202
OPC DRUM UNIT HIGH VOLTAGE POWER SUPPLY TRANSFER CHARGER

DEVELOPER BIAS
6 24 1 J13 J9 5 J11 4 1
202278 E112 PAPER EMPTY SENSOR
+5 /WASTE TNRLOW DGND 202393 S201
1 J1 4
TONER SENSOR BOARD
CN1 CN2
TONER SENSOR
PEPWR 1 PEMPTY DGND 3
DEVELOPER
Block Diagram 81. Power Supplies Electrical
87
8.3 Low Voltage Power Supply 8.3.1 Removal and Disassembly

NOTE: If you are replacing a Fuse or converting the LVPS input voltage, skip to the next section, Input Voltage Conversion and Fuse Replacement.
1. Open the Clamshell, remove the OPC Drum Unit, Developer Unit, Waste Toner Container, and any paper present in the printer. 2. Remove the Lamp Connector cover by removing 1 Screw, then disconnect the Fuser Lamp Connector and the Thermistor Connector from their mating Connectors on the Stepper Motor Board Frame. See Figure 81.
88
Step 2 Step 4
Figure 81. Disconnecting the Connectors 3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Figure 82. NOTE: Upon installation, the groove on the bottom of the Right Inside Cover should straddle the top edge of the right side of the Tractor Frame. (See detail in Figure 82.)
89
Step 3
Figure 82. Removing the Right Inside Cover 4. Separate the Fuser Lamp Connector and the Thermistor Connector of the LVPS from the Stepper Motor Board Frame by releasing the Locking Tabs and pushing the Connectors through the hole in the Printer Base Plate. See Figure 81. 5. Place the printer on a phone book or other similar item so that the Bottom Cover edges are not resting on the item. Press gently to release the 2 Locking Tabs on the right side of the Bottom Cover, then gently lower this side. Slide the Bottom Cover slightly to the right to release the locking tabs on the left side, then lower the Bottom Cover away from the printer and over the phone book. See Figure 83.
810
Figure 83. Bottom Cover Removal 6. Remove the printer from the phone book and disconnect 2 Cables from the front of the LVPS. See Figure 84.
811
Figure 84. Removing the LVPS Cables
812
7. Remove 2 Screws from the rear of the Base Frame, then lift the LVPS to clear the Base Frame. Push the Power Switch to the OFF position, then slide the LVPS toward the rear of the printer. Use care to avoid damaging the Power Switch. Once the Power Switch is partially past the Frame, switch it to the ON position and slide the LVPS free of the Base Frame. Feed the Lamp Power Wire Harness through the Printer Base Plate. See Figure 85. CAUTION: Use care to avoid damaging the Fuser Lamp Connector. Ensure that it does not catch on the Base Plate. When reinstalling the Lamp, be sure that you route the Fuser Lamp Connector through the Base Plate before you install the LVPS into the Base Frame. See Figure 86. When installing the LVPS, ensure that the bottom front of the supply is locked under the locking tabs on the base frame. See Figure 87.
NOTE:
813
Figure 85. Removing the LVPS
814
Cable Routing
Figure 86. LVPS Cable Routing
815
Figure 87. LVPS Locking Tabs 8. To remove the LVPS Cooling Fan, disconnect the Cable from Connector CN3, remove 2 Screws, then remove the Cooling Fan.
816
8.3.2 Input Voltage Conversion and Fuse Replacement

Use this procedure to replace a fuse in the LVPS, or to convert the LVPS input voltage from 115 VAC to 230 VAC or from 230 VAC to 115 VAC. 1. Place the printer on a phone book or other similar item so that the Bottom Cover edges are not resting on the item. Press gently to release the 2 Locking Tabs on the right side of the Bottom Cover, then gently lower this side. Slide the Bottom Cover slightly to the right to release the locking tabs on the left side, then lower the Bottom Cover away from the printer and over the phone book. See Figure 88. 2. Remove the printer from the phone book and disconnect 2 Cables from the front of the LVPS. See Figure 89.
Figure 88. Bottom Cover Removal
817
Figure 89. Removing the LVPS Cables
818
3. Remove 2 Screws from the rear of the Base Frame, then lift the LVPS to clear the Base Frame. Push the Power Switch to the OFF position, then slide the LVPS toward the rear of the printer. Use care to avoid damaging the Power Switch. Once the Power Switch is partially past the Frame, switch it to the ON position and slide the LVPS free of the Base Frame. See Figure 810. CAUTION: Use care to avoid damaging the Fuser Lamp Connector. Ensure that it does not catch on the Base Plate. When reinstalling the Lamp, be sure that you route the Fuser Lamp Connector through the Base Plate before you install the LVPS into the Base Frame. See Figure 811. When installing the LVPS, ensure that the bottom front of the supply is locked under the locking tabs on the base frame. See Figure 812.
NOTE:
819
820
Cable Routing
821
Figure 812. LVPS Locking Tabs 4. Remove 1 Screw from the tie wrap that secures the Lamp Power Wire Harness. 5. To change the input voltage of the LVPS, remove 1 Screw and remove the Connector Bracket. Disconnect the Cable from Connector CN5 or CN6 and connect it to the free one. CN5 is for 115 VAC and CN6 is for 230 VAC. Place the Connector Bracket over the free Connector and reinstall 1 Screw. See Figure 813.
822
2 3
115V Position
2 3
230V Position
Figure 813. Changing LVPS Input Voltage
823
6. Replace Fuse F1, F2, or F3 as needed.

Reverse all of the Steps listed above. The following table lists the Cable Connectors and Fuses for the LVPS, together with their respective functions and their destinations: Table 81. Low Voltage Power Supply Connectors and Fuses
Connector or Fuse
CN1
Function
Engine Controller Board Power (+5V) Stepper Motors Controller Board Power
Destination
J7 on Backplane Board CN1 on Stepper Motors Controller Board J8 on Backplane Board LVPS Lamp Connector LVPS LVPS
CN2
Engine Controller Board Power (+24V, "12V) and Signals LVPS Cooling Fan Fuser Lamp 115 VAC Input Power 230 VAC Input Power
CN3 CN4 CN5 CN6
F1 F2 F3
Lamp Fuse 115 VAC 230 VAC
8.3.4 Adjustment
No adjustment of the LVPS is required.
824
8.4 High Voltage Power Supply 8.4.1 Removal and Disassembly

1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, and any paper present in the printer. 2. Remove the Left Side Cover of the printer. See Figure 814. a. Remove 2 Screws from the Left Side Cover. b. Loosen, but do not remove, 1 Screw on the Base Plate. This loosens the Mounting Bracket so it can be slid free of the Base Plate. c. Lift the front edge of the Cover to disengage the Locking Tabs, then slide the Cover toward the rear of the printer to disengage the Bracket from the Screw in the Base Plate.
Step 2b Step 2a
Locking Tabs
Figure 814. Removing the Left Side Cover 3. Remove the Front Plastic Paper Guide of the Transfer Charger by pressing down on the ends and sliding it to the left. This disengages the Locking Tabs and the Guide can be easily removed. See Figure 815.

825
Step 4
Step 6 Step 5
Step 3
Step 7
Figure 815. Removing the Transfer Charger Paper Guides
826
4. Remove the Transfer Charger Paper Guide by gently pressing the Release Tabs at the rear of the Guide toward the front of the printer. Lift the rear of the Guide to clear the Tabs of the Slots, and release the Front Tabs by rotating the Guide toward the front of the printer. See Figure 815. 5. Remove the Static Brush and Rear Plastic Paper Guide from the Corona Assembly by removing 2 Screws. See Figure 815. NOTE: When reinstalling the Static Brush, ensure that the Brush Frame is in front of the Locking Tab for the Corona Assembly. See Figure 816.
Static Brush Is Placed In Front Of Retaining Tab
Figure 816. Reinstalling the Static Brush 6. Remove 2 Screws and lift the Corona Assembly up slightly while sliding it to the left to disengage the Locking Tabs. See Figure 815. 7. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the printer by lifting the rear portion of the Guide out first. This helps the Guide clear the Contacts for the HVPS and the Transfer Charger Frame. Disengage the Locking Tabs at the front of the Guide from the Tension Roller Frame. See Figure 815. 8. Remove the Fuser Heat Shield. See Figure 817.
827
Step 8
Step 12
Cover overlaps tractor assembly side frame Cover overlaps tractor assembly side frame
Step 14
Step 11 Step 13
Step 9
Step 10
Figure 817. Removing the Fuser
828
9. Remove the Lamp Connector Cover by removing 1 Screw and disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Figure 817. 10. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Figure 817. NOTE: Upon installation, the groove on the bottom of the Right Inide Cover should straddle the top edge of the right side of the Tractor Frame. See detail in Figure 817.
11. Remove the Tractor Encoder Cover by removing 1 Screw. See Figure 817. NOTE: Upon installation, the groove on the bottom of the Encoder Cover should straddle the top of the left end of the Tractor Frame. See detail in Figure 817.
12. Remove the Tractor Paper Guide by removing 1 Screw from the center rear of the Tractor Frame. See Figure 817. 13. Disconnect the Encoder Cable from the Connector on the Base Plate. See Figure 817. 14. Remove the Tractor by removing 3 Screws, then lifting the left end of the Tractor out first. This clears the Encoder of the HVPS, and allows the Tractor room to move to the left so that the Tractor Stepper Motor can clear the Stepper Motor Board Frame. See Figure 817. 15. Disconnect the Cable from the Tractor Stepper Motor and remove the Tractor from the printer. 16. Remove 1 Screw from the rear of the HVPS Contact and slide it toward the rear of the printer to release the Front Locking Tab from the Printer Base Plate. See Figure 818.
829
Step 17
Step 16
Figure 818. Removing the HVPS 17. Disconnect the Cable from the rear of the HVPS and remove 1 Screw from the rear of the HVPS. Slide the HVPS toward the rear of the printer to release the Front Locking Tab from the Base Plate. See Figure 818. NOTE: Upon installation, ensure that the HVPS Cable is properly routed through the grooves in the HVPS Cover.
830

Reverse Steps 1 through 17 listed above.
8.4.3 Adjustment
With rare exceptions, the high voltage power supply should not require adjustment. However, in the event that adjustment is required in order to return the printer to specification, use the HVPS adjustment procedure that follows. WARNING: HIGH VOLTAGES are present in numerous places throughout the High Voltage, OPC, and Developer assemblies when the printer is turned on.
The table that follows lists specifications, connections, and control interface for the HVPS. Use these as a guide to adjusting the small controls on the side of the HVPS itself. See Figure 819. NOTE: The user-adjustable developer bias knob on the top of the HVPS must be set to 3 when making the following adjustments. Table 82. High Voltage Power Supply Adjustments Engine Controller Connector J101 J102 J103 J104 HV Supply Connector Channel 6 5 4 3 CH1 CH4 CH3 CH6 CN1 CN2 CN3 CN6 HV Output Connector Adjust VR1 VR22* VR31 VR61 Output Value 40025mA 55050 VDC 4.60.1 kVDC 720 VDC (parasitic from charge) Definition +24 VDC supply Charge corona Developer bias Transfer corona Charge grid
Signal +24V Charge Develop Transfer
BGND
J106
Analog ground
*With VR21 set to 3.
831
Adjustments:
CH2 CH3 CH1 CH6
CN2
CN6
Lockdown tabs
Contactor Assembly
CN3
Figure 819. High Voltage Test and Adjustment Points
832

UserAdjustable Developer Bias Adjustment
CN1
HVPS ADJUSTMENT PROCEDURE 1. Turn off the printer. 2. Open the printer and remove the OPC Drum Unit and the Developer Unit. 3. Set the user-adjustable developer bias knob to 3. NOTE: The user-adjustable developer bias knob is the green knob located on the top of the HVPS. This knob is also called VR21. Turning the knob varies the high voltage to the developer unit. See Figure 819.
4. Disable the following: S Paper empty switch S Cover interlock switch S Top-of-form switch S OPC drum switch 5. Turn on the printer and wait for the printer to display the error message, 03 ADD TONER AND CHK WASTE BOTTLE on the LCD. 6. Take the printer offline by pressing the On Line key. The top line of the LCD should show OFFLINE. 7. Press the Next key until DIAGNOSTICS appears on the bottom line of the LCD. 8. Press the Down key. Press Next until TEST PRINT appears on the bottom line of the LCD. 9. Press Down. Press Next until NO. OF PAGES appears on the bottom line of the LCD. 10. Press Down. Press Next until CONTINUOUS appears on the bottom line of the LCD. 11. Press Enter. (If you receive the message ENTER SWITCH LOCKED, then unlock it by pressing Up and Down simultaneously. Then press Enter again.) The number of pages to print has now been set to Continuous. This is indicated by an asterisk (*) character on the LCD. 12. Press Up. Press Next until START TEST PRESS ENTER appears on the LCD. 13. Press Enter. The message TEST PRINTING appears on the LCD. At this point, the printer should be attempting to print. 14. Using a high voltage probe and a DVM, check the voltages at the points listed in the table on page 831. NOTE: A high voltage probe must be used when measuring each of these voltages. Even a good DVM used without a high voltage probe will load the circuit enough to produce erroneous readings.
833
15. Stop the test by pressing Enter. 16. Turn off the printer. 17. Restore the following to their normal (non-disabled) states: S Paper empty switch S Cover interlock switch S Top-of-form switch S OPC drum switch 18. Install the OPC Drum Unit and the Developer Unit, then close the printer top.
834
CLAMSHELL
HIGH VOLTAGE SUPPLY
LEFT FRAME
BASE PAN
STEPPER MOTOR & CONTROL BOARD HOUSING
ENGINE CONTROLLER BOARD
BOTTOM FRAME
BACKPLANE BOARD
DATA CONTROLLER BOARD
BOTTOM COVER
Controller Boards
91
9.1 Data Controller Board Parts List

Callout 1 Name Controller Assembly, Data, L1024 Vendor Part No. Printronix Part No. 704598001
Data Controller Board
92
9.2 Engine Controller Board Parts List

Callout 1 2 Name Engine Controller Board, L1024 Backplane Board, L1024 Vendor Part No. Printronix Part No. 202505551 704539108 202289552 704539107
Bottom Frame
Engine Controller Board Backplane Board
Engine Controller and Backplane Boards
93
9.3 Stepper Motors Controller Board Parts List

Callout 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Name Stepper Motor Board Frame Assembly Cover, Side, LVPS Frame, Stepper Motor Board Board, Stepper Motor Fan, Ozone Actuator, Cover Open Actuator, Drum Sensor Label, Inlet Hole Cover Screw, PPH, CLFW, 3x6mm, Zinc (8) Screw, PPH, CLFW, 3x10mm, Zinc Screw, PPH, CLFW, 3x30mm, Zinc (4) Wire Harness, Thermistor Wire Harness, Lamp Cable, Stepper Motor Control Wire Harness, Power, Controller Board Tie Wrap, Beaded, Motor Board Harness Vendor Part No. Printronix Part No. 202168502 200673001 202169552 202170551 704539110 202171551 704539111 202172001 704539112 202173002 704539113 202174001 030030306 030030310 030030330 202200551 202576551 202299551 202298551 202391001
94
Left side view
13 1 12 1 10 1 9 1 9 2
1 Ref 8 1
9 2 6 1 7 1
9 1
9 2
11 4
3 1
5 1 16 1
4 1 15 1 2 1
14 1
Right side view
Stepper Motors Controller Board
95
9.4 Floppy Disk Drives Parts List

Callout 1 2 3 4 5 6 Name Disk Drive Assembly, 3.5 Inch, L1024 Cable Kit, L1024 Disk Drive, Floppy, 3.5 Inch 2 MB Screw, FL 90D, M3x5, Phil., STL/ZN Clamp, Flat, Cable, 2 Hole Mount Pad, Cushion, Flat Cable Clamp Vendor Part No. Printronix Part No. 704627001 704612001 202377001 202404002 202403001
96
Drive A (Standard)
Drive B (Optional)
Floppy Disk Drives
97

The printer has three Controller Boards: S Data Controller Board S Engine Controller Board S Stepper Motors Controller Board The Data Controller Board oversees and coordinates all printer functions. It communicates with the following: S Control Panel S Floppy Disk Drives S Engine Controller Board S Host Computer The Engine Controller Board acts as interface between the Data Controller Board and the electromechanical portions of the printer. The Stepper Motors Controller Board controls the various stepper motors in the printer. The main function of the stepper motors is moving the paper.
9.5.2 Electrical
See the block diagram in Appendix B for an overview of the connections between the controller boards and the other areas of the printer.
98
9.6 Data Controller Board 9.6.1 Removal and Disassembly

WARNING: To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards and components. Do not remove or replace the NVRAM on the Data Controller Board. The NVRAM contains a lithium battery that can explode if the NVRAM is replaced incorrectly. NVRAM is replaced only at the factory.
1. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board. See Figure 91. CAUTION: The Floppy Disk Drive Data and Power Cables must be disconnected from the Data Controller Board before the board can be removed from the printer.
2. Slide the Data Controller Board out of the printer part of the way, until you can gain access to the Floppy Disk Drive Power Cable Connector (J5) and Data Cable Connector (J10) on the board. See Figure 91. 3. Disconnect the Floppy Disk Drive Power Cable from Connector J5 on the Data Controller Board. 4. Disconnect the Floppy Disk Drive Data Cable from Connector J10 on the Data Controller Board. 5. Slide the Data Controller Board out the rest of the way, and remove it from the printer.
99
Screw (4) J10 J5
Figure 91. Removing Data Controller Board

9.6.3 Adjustment
No adjustment of the Data Controller Board is necessary.
910
If you have not already done so, run the engine self-test. (Refer to the engine self-test information in Chapter 13.) If errors or other problems occur when running the engine self-test, then the problem is most likely not in the Data Controller Board or the host computer. The problem, in this case, is more likely to be in the Engine Controller Board, or in other areas of the printer engine. Refer to the troubleshooting information in Chapter 13. If the engine self-test runs with no errors, however, then the Data Controller Board or host computer is probably at fault. Run one of the Data Controller Board printing self-tests. These tests are accessible from the Diagnostics menu, using the Control Panel keys. (Refer to the Setup Guide for instructions on accessing and running these tests.) Running a printing self-test will isolate the error to either the Data Controller Board or the host computer. If the printing diagnostic tests run correctly, the problem is most likely in the host computer. However, it could also be in one of the following areas: S The Data Controller Board interface to the host computer (located on the Data Controller Board). S The interface cables between the Data Controller Board and the host conputer. S A configuration mismatch between the printer and the host computer. NOTE: If you suspect a configuration problem, refer to the Setup Guide for instructions on properly configuring the printer. Refer to the documentation for your host computer for information on configuring your host computer to work with the printer.
If the printing diagnostic tests do not run correctly, or do not run at all, and the engine self-test ran correctly, then the problem is most likely to be in the Data Controller Board, not the host computer. Run the Data Controller Board power-up self-test, as described below.
Data Controller Board Power-Up Self-Test

Turn off power to the printer. When you turn the printer power back on, look through the three small round holes located on the vertical rear panel of the Data Controller Board, and observe the three tiny green LEDs mounted flat on the board. These LEDs serve as diagnostic indicators for the boards power-up self-test. The LEDs are identified as L1, L2, and L3, as shown in Figure 92. LEDs L1 and L2 display information about the boot sequence. LED L3, described later, indicates CPU activity (or the lack of it) for the microprocessor on the Data Controller Board.
911
L1 RS232/RS422 TEST 5V
L2
L3
PARALLEL
Figure 92. Data Controller Board Diagnostic LED Locations
As the Data Controller Board starts and initializes, LEDs L1 and L2 will indicate the various portions of the boot sequence, as shown in Table 91. Table 91. Data Controller Board Boot Sequence L1 Off On Off On On Off On Off L2 Off On Off On Off On On Off Meaning Initial State Running DRAM Diagnostics Running I/O Diagnostics Reading Sector 0 from Disk Searching for Boot File Loading Boot File Preparing for Execution Normal Execution State
912
If an error occurs during the Data Controller Board power-up self-test, the initialization sequence will stop, and the board will report an error. The board reports the error by beeping the speaker, flashing L1, and flashing L2, all in unison, to signal the error code. The error code will be signalled repeatedly, as long as power to the Data Controller Board remains on. Table 92 lists the beep and LED error codes. Table 92. Data Controller Board Beep and Diagnostic LED Error Codes
Diagnostic Status
ROM Checksum TestFail DRAMBank 1 Failure DRAMBank 2 Failure DRAMBank 3 Failure DRAMBank 4 Failure Vector Interrupt TestFail Autovector InterruptFail Front Panel PresenceFail Front Panel LCD Pattern Test Key:
LED Flash/Beep Pattern

Visual Detection
LCD Message Displayed

None None None None None None None Not Applicable RUNNING SELF TEST ....
= L1, L2, and the Beep are all on together for 500 msec. = Pause for 2 sec.
913
The third LED, LED L3, indicates the relative amount of CPU activity. Referring to Figure 93, when the CPU is 100% utilized, L3 will be off. L3 will be on at full intensity when the CPU is idle, such as when the CPU tasks are running faster than the printer engine speed. During normal operating conditions, LED L3 will be somewhere between the two extremes of continuously on and continuously off, and will appear dimmed. This condition is indicated by the gray area labelled Normal CPU Usage Range in Figure 93. Increasing CPU utilization causes L3 to decrease in intensity, and vice-versa.
ON
CPU Idle
Normal CPU Usage Range
OFF
CPU 100% Utilized
Figure 93. Data Controller Board LED L3 Interpretation
914
9.7 Engine Controller Board 9.7.1 Removal and Disassembly

1. Open the Clamshell, remove the OPC Drum Unit, Developer Unit, Waste Toner Container, and any paper present in the printer. 2. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board. 3. Slide the Data Controller Board out of the printer part of the way, until you can gain access to the Floppy Disk Drive data and power connectors on the board. See Figure 91 on page 910. 4. Disconnect the Floppy Disk Drive data and power connectors from the Data Controller Board. 5. Slide the Data Controller Board out the rest of the way, and remove it from the printer. 6. Place the printer on a phone book or other similar item so that the Bottom Cover edges are not resting on the item. Press gently to release the 2 Locking Tabs on the right side of the Bottom Cover, then gently lower this side. Slide the Bottom Cover slightly to the right to release the locking tabs on the left side, then lower the Bottom Cover away from the printer and over the phone book. See Figure 94.
915
Figure 94. Removing Bottom Cover 7. Remove the printer from the phone book. Remove the Screw from the left side of the Base Frame that secures the Engine Controller Board. 8. Unplug the Engine Controller Board from the Backplane Board and remove the Engine Controller Board from the printer through the opening in the rear of the printer.

9.7.3 Adjustment
No adjustment of the Engine Controller Board is necessary.
916
9.8 Stepper Motors Controller Board 9.8.1 Removal and Disassembly

1. Open the Clamshell, remove the OPC Drum Unit, Developer Unit, and any paper present in the printer. 2. Remove the Lamp Connector Cover by removing 1 Screw and disconnect the Fuser Lamp and Thermistor Connectors from the Right Side Frame. See Figure 95 and Figure 96. Step 2 Step 6 Step 3 Step 10
Detail 91
Step 5
Step 3
Figure 95. Removing Various Parts
917
3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. NOTE: Upon installation, the groove on the bottom of the Right Inside Cover should straddle the top edge of the right side of the Tractor Frame. See Detail 91 in Figure 95.
4. Open the Printer Front Cover and remove the LCD Control Panel by removing 2 Screws. 5. Remove the Right Side Cover by removing 3 Screws. 6. Remove 2 Screws from the Ozone Filter Case and remove it from the printer. 7. Release the Fuser Lamp Connector and the Thermistor Connector from the Stepper Motor Board Frame by pressing in on the Locking Tabs. See Detail 92 in Figure 96.
918
Detail 92
Step 2 Step 7
Figure 96. Releasing Heater Lamp and Thermistor Connectors
919
8. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Remove the Frame Cover, and disconnect 7 Cables from the Board. These Cables are at connectors CN1, CN2, CN3, CN4, CN5, CN6 and CN8. See Figure 97 and Detail 93 in Figure 97. NOTE: The 3 Stepper Motor Cables connect to Connectors CN3, CN4, and CN5 in the order the Motors appear in the printer: the Gear Motor connects to CN3, the Tractor Motor connects to CN4, and the Fuser Motor connects to CN5.
920
Detail 93
CN3
CN4 CN2
CN5 CN8 CN6
CN7
CN1
Left side view
Stepper Motors Controller Board Connectors Detail
Step 12 Step 8
Step 11
Right side view

Figure 97. Stepper Motors Controller Board Removal and Connectors Detail
921
9. Remove the Fuser Heat Shield. See Figure 98. 10. Remove the Tractor Paper Guide by removing 1 Screw, then disconnect the Cable from the Fuser. Remove 1 Screw from the Cable Tie to release the Cable from the Base Plate of the printer. See Figure 98. 11. Remove 2 Screws from the Stepper Motors Controller Board and remove it from the printer. See Figure 97.
922
Step c
Step b
Depress white retaining levers to release fuser roller assembly from fuser base
Step 9
Step d
J1 Connector
Step e
Step 10
Figure 98. Preparation for Removing the Stepper Motor Board Frame
923
NOTE:
The Stepper Motor Board Frame cannot be removed unless the Fuser Base has been removed from the printer. Therefore, remove the Stepper Motor Board Frame only if absolutely necessary. Follow the steps below (see Figure 98) before removing the Stepper Motor Board Frame (Step 12).
a. Open the Paper Exit Guide at the rear of the Fuser Base so that it is not in contact with the Fuser Roller Assembly. b. Depress the Fuser Assembly Retaining Lever on each side of the printer so that the Fuser Assembly is free to move. c. Lift the Fuser Assembly free of the Fuser Base, then remove it from the printer.
d. Disconnect the Fuser Sensor Board by removing the Cable at Connector J1. e. Remove 2 Screws from the rear of the Fuser Base and remove it from the printer. 12. Remove 2 Screws from the Stepper Motor Board Frame and remove the Frame. See Figure 97 on page 921.
DISASSEMBLY
NOTE: Except for the Ozone Fan, all of the components listed below can be removed from the printer without first removing the Stepper Motor Board Frame. The Ozone Fan can be removed from the Frame if the LCD Control Panel and Bracket are first removed from the printer.
1. Disconnect the Cable from Connector CN7, remove 4 Screws from the Ozone Fan, and remove the Fan from the Frame. 2. Remove 2 Screws, then remove the Stepper Motors Controller Board from the Frame. 3. Remove 1 Screw, then remove the OPC Drum Spring. 4. Remove 1 Screw, then remove the Cover Open Spring.

Reverse all of the Steps listed above. Table 93 lists the connectors on the Stepper Motors Controller Board, together with their respective functions and destinations. Figure 99 shows the locations of the connectors on the board.
924
Table 93. Stepper Motors Controller Board Connectors CONNECTOR CN1 CN2 CN3 CN4 CN5 CN6 CN7 CN8 FUNCTION Stepper Motors Controller Board Power Stepper Motors Controller Board Control Main Stepper Motor Tractor Stepper Motor Fuser Stepper Motor Fuser Cam Motor and Clutch Ozone Fan Thermistor Power DESTINATION CN2 on LVPS J6 on Backplane Board Main Stepper Motor Tractor Stepper Motor Fuser Stepper Motor Fuser Cam Motor and Clutch Upper Board Housing Fan Fuser Lamp Connector
CN3
CN4
CN5
CN2 CN1 CN7 CN8
CN6
Figure 99. Stepper Motors Controller Board Connectors
9.8.3 Adjustment
No adjustment of the Stepper Motors Controller Board is necessary.
925
9.9 Floppy Disk Drives 9.9.1 Removal and Disassembly

NOTE: Some printers will have only one Floppy Disk Drive installed. The second, or Drive B, Floppy Disk Drive is an option. This procedure is written assuming that the printer being serviced has both Floppy Disk Drives installed.
1. Open the Clamshell. Remove any paper present in the printer. Remove the OPC Drum Unit, the Developer Unit, and the Waste Toner Container. 2. Remove the Front and Rear Paper Guides from the printer. 3. Remove the Floppy Disks from the Floppy Disk Drives. 4. Disconnect the Power Cord and Data Cable from the rear of the printer. 5. Remove the plastic Floppy Disk Drive Guide (Bezel) from the front of the printer by pressing in on the Locking Tabs. See Figure 910. 6. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board. See Figure 91 on page 910. CAUTION: The Floppy Disk Drive Data and Power Cables must be disconnected from the Data Controller Board before the board can be removed from the printer.
7. Slide the Data Controller Board out of the printer part of the way, until you can gain access to the Floppy Disk Drive Power Cable Connector (J5) and Data Cable Connector (J10) on the board. See Figure 91 on page 910. 8. Disconnect the Floppy Disk Drive Power Cable from Connector J5 on the Data Controller Board. 9. Disconnect the Floppy Disk Drive Data Cable from Connector J10 on the Data Controller Board. 10. Slide the Data Controller Board out the rest of the way, and remove it from the printer. 11. With paper and all Consumables removed, especially the Waste Toner Container, turn the printer upside down. Carefully press on the 4 corners of the Bottom Cover to release the Locking Tabs from the Base Plate and remove the Bottom Cover. Turn the printer rightside up. See Figure 94 on page 916. 12. Remove 2 Screws from the front and 1 Screw from the left side of the Floppy Disk Drive Frame. See Figure 910. 13. Remove the Floppy Disk Drive Frame (with Drives and Drive Cables attached) from the printer Base Frame, through the front opening of the printer.
926
Step 12
Floppy Disk Drive Frame
Floppy Disk Drive Guide (Bezel)
Floppy Disk Drive Frame (Ref.)
Step 5
Figure 910. Removing Drive Frame from Printer
927
DISASSEMBLY
1. Observe the orientation of the Data Cable on the rear of each Floppy Disk Drive, and make a note of it for reference later when you reinstall the Drives. See Figure 911. 2. Disconnect the Data and Power Cable Connectors from the rear of each Floppy Disk Drive. NOTE: When you install a Floppy Disk Drive, be sure to orient the Data Cable correctly when you connect it to the rear of the Drive.
3. Remove 4 Screws from the bottom of each Floppy Disk Drive and remove the Drives from the Floppy Disk Drive Frame. NOTE: When you replace a Floppy Disk Drive, be sure to correctly set the Drive Addressing Jumpers and/or Switches on the new Drive before you install it. The first (or only) Drive in the printer must be addressed as Drive A. If the optional second Drive is present, it must be addressed as Drive B.
928
Step 2
Drive A (Standard)
Drive B (Optional)
Step 3
Figure 911. Removing Drives from Drive Frame
929

Reverse all of the Steps listed above. NOTE: When you install a Floppy Disk Drive, be sure to orient the Data Cable correctly when you connect it to the rear of the Drive. When you replace a Floppy Disk Drive, be sure to correctly set the Drive Addressing Jumpers and/or Switches on the new Drive before you install it. The first (or only) Drive in the printer must be addressed as Drive A. If the optional second Drive is present, it must be addressed as Drive B.
NOTE:
9.9.3 Adjustment
No adjustment of the Floppy Disk Drives is necessary.
930
9.10 Expansion C/T Removal/Installation 9.10.1 Removal (see Figure 912)

1. Remove the data controller board from the printer, as described in section 9.6.1. 2. Loosen the thumbscrew (4) on the C/T board (3) until the screw is released from the standoff (5). 3. Remove the screw securing the I/O plate to the rear of the card cage (1). 4. Carefully lift the C/T board out of the data controller cutout (6) and off the expansion connector (7).
9.10.2 Installation (see Figure 912)

1. Remove the data controller board from the printer, as described in section 9.6.1. 2. Remove the screw holding the I/O cover plate to the L1024 data controller pan (1). Save the screw. 3. Screw the standoff (5) onto the pan, through the hole next to C54. 4. Carefully install the C/T card (3) with the expansion connector (7) onto the board. 5. Using the screw which held the I/O cover plate (1), screw the I/O plate (2) to the pan. Tighten the thumbscrew (4) to the standoff (5). 6. Re-install the data controller as described in section 9.6.2.
9.10.3 Expansion C/T Parts List

Callout 1 2 3 4 5 6 7 Name Screw Card Cage ExpansionCT PCBA Screw, Captive Standoff, Hex, 3/16 inch, M/F, .813 Lg. L1024 Data Controller Board Expansion Connector Printronix Part No. Ref Ref 152319001 Ref Ref Ref Ref
931
4 3
5 7
6 2
Figure 912. ExpansionC/T Board
932
LCD Keypad
Control Panel
101
10.1 Control Panel Parts List

Callout 1 2 3 Name Control Panel Assembly, L1024 Screw, PPH, W/CLFW, M3x8, Zinc (2) Overlay Sheet Vendor Part No. Printronix Part No. 202117552 704539048 030130308 202316001
1 1
2 1 3 1
2 1
Connector CN
Control Panel
102

The control panel has a 16-character by 2-line Liquid Crystal Display (LCD). In addition, there are three status lights and seven keys. The keys are membrane-type switches with the function printed on each one. The status lights are used to monitor the printer state, data in the buffer, and the online status. The LCD allows the user to display the programmable functions that control the printer. It also shows the printer status and other control information.
10.2.2 Electrical
The control panel is connected to the engine controller via connector CN on the back of the display panel. This is connected to a straight-through 26-pin connector and via a 26-wire cable to the engine controller at J3. This connector is keyed to make sure it can be plugged in only one way. The following table lists the interface cable pin connections and their functions: Table 101. Control Panel Interface Signals Pin Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Function No connection Ground +5 volts (RS) register select; 0 for instruction register, 1 for data register (R/W) read/write select; 0 for write, 1 for read (E) strobe to signal start of data read or write (DB0) Data bit 0 (DB1) Data bit 1 (DB2) Data bit 2 (DB3) Data bit 3 (DB4) Data bit 4 (DB5) Data bit 5 (DB6) Data bit 6 (DB7) Data bit 7 (SW Reset) Reset Key (SW Online) Online Key
103
Pin Number 17 18 19 20 21 22 23 24 25 26
Function (SW FF) Page Eject (Form Feed) Key (SW Menu) Menu Key (SW Store) Store Key (SW Up) Up-Arrow Key (SW Down) Down-Arrow Key (LED Ready) Ready LED (LED Online) On Line LED (LED Data) Data LED (LEDRSV1) Reserved LED output, not currently used (LEDRSV2) Reserved LED output, not currently used
104
Following is a block diagram. See Appendix B for a complete electrical block diagram.
202298 S208 AGND AGND PWROFF /HEAT (TO ENGINE CONTROLLER BOARD) +5 /PRPOS 1 /PRINIT /SCPUP /SCPDN PJAM EJAM DGND +24 /PRFAN J1 (TO DATA CONTROLLER BOARD) J2 +24 BGND +12 12
202375 S207 DGND DGND DGND DGND J7 8 202294 S204 TO LSU
10
J8
BACKPLANE BOARD
J5 1 2 10 3 4 5 6 7 8 J3 (TO LCD CONTROL PANEL) RSVD Vss Vdd RS R/W E DB0 DB1 9 10 11 12 13 14 15 16 DB2 DB3 DB4 DB5 DB6 DB7 /SWRST /SWONL J3 24 1 17 /SWFF 18 /SWMENU 19 /SWSTOR 20 /SWUP 21 /SWDWN 22 /LRDY 23 /LONLN 24 /LDATA J4 +12 1 /QLED +24 BGND /PMON 5 /PMRDY +5 DGND /BD +5 10 DGND /LDON /LVIDEO LVR 14
201153 S203 J6
LCD CONTROL PANEL
+5 +5 +5 +5
1 J10

DEVELOPER BIAS
6 24 1 J13 J9 5 J11 4 1
1 J1 4
TONER SENSOR BOARD
CN1 CN2
TONER SENSOR
DEVELOPER
Block Diagram 101. LCD and Keypad
105
10.3 Control Panel 10.3.1 Removal and Disassembly

1. Open the printer clamshell. 2. Open the front cover. See Figure 101.
Step 2
Step 3
Step 4
Figure 101. LCD Control Panel Removal 3. Remove the screw on left front of the control panel. 4. Remove the screw on the bottom right side of the control panel. 5. Lift the control panel upward and to the right to disengage the tab and shaft. CAUTION: Be careful not to damage the cable.
6. Disconnect the cable and remove the LCD panel. NOTE: Do not remove the board from the control panel as the LCD is aligned to panel mask and buttons. The entire assembly should be replaced if any problems occur with any of the components.
106
10.3.2 Reassembly and Replacement Reverse Steps 1 through 6 above.
10.3.3 Adjustment
No adjustment of the Control Panel Assembly is necessary.
10.3.4 Troubleshooting Overview

The printer LCD panel displays the status of the printer and user-changeable programming information. Printer status information is transmitted by the data controller to the LCD control panel via the 26-pin cable See Figure 102. This cable plugs into the Backplane Board at J3 and connects to the display panel at connector CN. There are seven keys (membrane-type switches) on the panel that allow the user to program various printer configurations. There are three LEDs that display READY status, ON LINE status, and data in the printer buffer.
IC2
IC1
CN
Figure 102. LCD Control Panel Board, Rear View
Symptoms
There are several symptoms that may lead you to suspect a bad display panel: S The LCD display may be missing a row of pixels, or S The control panel keys may not be operating properly, or S A status LED may be defective.
107
If you observe any of these symptoms, replace the entire display panel, since there are no replaceable parts in it. 1. Missing row of pixels. The quickest way to check whether the panel is good or not is by substitution. If the problem disappears when you replace the panel, the old panel was bad and no further work is required. If, however, the panel is still missing pixels, perform a continuity check of the 26-pin cable that goes to the data controller. Begin by removing the bottom cover of the printer. The panel cable is a one-to-one type that plugs into the Backplane Board at J3. The pinout of the cable is shown in Table 101 on page 103. If both the panel and the cable check out OK, replace the data controller. 2. Keys not operating properly. The seven keys on the panel have a decal attached to the plastic housing that makes up the bulk of the display panel. The key coverings, in turn, press against seven small switches that are on the LCD printed circuit board. Two of the probable failure modes for the keys are: S The key covering is not making contact with the switch underneath it, or S The switch itself is bad. Check these possibilities as follows: a. Turn the printer off and remove the display panel. b. Locate the pin on connector CN for the suspected bad key. See Figure 102. c. Place one lead of an ohmmeter on pin 2 (ground) of CN and the other lead on the pin of the suspected bad key. Try pressing the key and see if the reading goes from open to closed. If not, then replace the display panel.
d. If the ohmmeter reading does cycle from open to closed, then check the wiring harness, the backplane board, and the data controller board.
108
Chapter 11 Laser Scanning Unit (LSU) Subsystem
Top Cover
LSU Assembly
Clamshell Frame
LSU Subsystem
111
11.1 LSU Parts List 11.1.1 LSU Assembly

Callout 1 2 3 4 5 6 7 8 Name LSU Assembly, L1024 Housing, LSU Top Cover, LSU Label, S/N, LSU Label, Warning, Laser Label, Warning, LSU Seal Seal, Drum, LSU Screw, PPH, CLFW, M3x8, Zinc (3) Vendor Part No. Printronix Part No. 202118551 202395551 202396001 202397001 200892001 200893002 202575002 030130308
112
7 1
1 1
8 3 4 1
6 1
2 1
5 1
3 1
Top View
LSU Assembly
113
11.1.2 Erase LED Assembly

Callout 10 11 12 13 14 15 16 Name Erase LED Assembly Cover, LED Assembly Mount, LED, Plastic Board Assembly, LED Screw, PPH, PTC, 3x8mm, Zinc (4) Screw, PPH, W/CLFW, 3x8mm (2) Bushing, LED Harness Vendor Part No. Printronix Part No. 200542551 702724001 200541001 200866001 200921551 030129308 030130308 202167001
12 1
14 4
11 1
13 1 10 Ref
16 1
15 2
Erase LED Assembly
114

The Laser Scanning Unit (LSU) is attached to the printer clamshell and includes the following basic subunits: S LSU Assembly. Generates the laser beam for page definition. S LED Array (Erase LEDs). Generates light to remove the residual charge from the OPC drum. S LSU Base Plate. Supports and positions the LSU; helps protect the LSU from the waste heat coming from the fuser.
11.2.2 Electrical
The LSU and LED units are connected via a single 14-wire cable to connector J4 on the Backplane Board as shown in the following block diagram. See Appendix B for a complete electrical block diagram.
115
10
J1
J2
J8
J7
BACKPLANE BOARD
J5 1 2 10 1 3 4 5 6 7 8 J3 (TO LCD CONTROL PANEL) RSVD Vss Vdd RS R/W E DB0 DB1 9 10 11 12 13 14 15 16 DB2 DB3 DB4 DB5 DB6 DB7 /SWRST /SWONL J3 24 1 17 /SWFF 18 /SWMENU 19 /SWSTOR 20 /SWUP 21 /SWDWN 22 /LRDY 23 /LONLN 24 /LDATA J4 +12 1 /QLED +24 BGND /PMON 5 /PMRDY +5 DGND /BD +5 10 DGND /LDON /LVIDEO LVR 14
201153 S203 J6
LCD CONTROL PANEL
8 202294 S204
TO LSU
1 J10

DEVELOPER BIAS
6 24 1 J13 J9 5 1 J11 3 4 1
1 J1 4
TONER SENSOR BOARD
CN1 CN2
TONER SENSOR
DEVELOPER
Block Diagram 111. LSU and LED Electrical
116
11.3 LSU Assembly 11.3.1 Removal and Disassembly

1. Open the Clamshell, remove 3 Screws from the Clamshell Frame, then lift the front of the Cover. This helps disengage the Locking Tabs of the LSU from the rear of the Cover. See Figure 111 and Detail 111. NOTE: When reinstalling the unit, the LSU must be properly located and seated in position by the locking pins in the LSU Housing and the holes in the LSU Base Plate. When reinstalling the Top Cover onto the Clamshell, make sure the Latch Assembly is properly oriented with the Release Lever. See Detail 113 on page 1111.
NOTE:
117
Top Cover
Clamshell Frame
Step 1
Figure 111. Top Cover Disassembly
118
Detail 111. Removing the Top Cover
119
2. Remove 4 Connectors of the LSU Cable from various points on the LSU. The Connectors are for the Erase LED Assembly, the Laser Driver, the Polygon Motor, and the Beam Detector. See Detail 112.
Top View
Detail 112. LSU Cables 3. Remove 3 Screws from the LSU Housing, then lift the LSU free of the LSU Base Plate. See Detail 112. CAUTION: The LSU is a sealed assembly. Do not attempt to open the LSU or repair it. Opening the LSU will cause it to become contaminated. If there is a problem with the LSU, replace it.

Reverse Steps 1 through 3 above. NOTE: When reinstalling the unit, the LSU must be properly located and seated in position by the locking pins in the LSU Housing and the holes in the LSU Base Plate. When reinstalling the Top Cover onto the Clamshell, make sure the Latch Assembly is properly oriented with the Release Lever. See Detail 113.
NOTE:
1110
Correct Latch Release Position
Detail 113. Clamshell Latch Reassembly
11.3.3 Adjustment
When reassembling the unit, ensure that the Clamshell and its Latch are oriented properly.
1111
11.4 Erase LED Assembly 11.4.1 Removal and Disassembly

1. Open the Clamshell, remove the Top Cover, disconnect the connector on the Erase LED Wire Harness, and remove the Erase LED Harness Bushing. Remove 2 Screws from the ends of the Erase LED Assembly Frame. See Figure 112. CAUTION: The Erase LED Wire Harness is hard-wired to the Erase LED Assembly. When working on the Erase LED Assembly, be careful not to damage any wiring.
1112
Top Cover
LED Connector Bushing
Figure 112. Erase LED Removal
1113
2. Remove the 2 Inner Screws and remove the Cover from the Erase LED Assembly. 3. Remove the 2 Outer Screws, then remove the entire LED Board and Mount together. NOTE: The Erase LEDs are soldered directly to the LED Board. Thus, if any LEDs are defective, replace the entire LED Board.

11.4.3 Adjustment
No adjustment of the Erase LED Assembly is necessary.
1114
Covers and Frame Components
121
12.1 Covers Parts List

Callout 2 3 4 5 6 7 8 9 10 11 12 13 17 18 19 20 22 23 25 Name Cover, Front LCD Control Panel Cover, Bottom Cover, Right Side Cover Assembly, Left Cover, Left Bracket, Mounting, Left Cover Screw, PPH, CLFW, 3x6mm, Zinc (3) Cover, Right Inside Cover, Lamp Connector Cover, Tractor Encoder Ozone Filter Case Screw, PPH, CLFW, 3x8mm, Zinc Screw, PPH, CLFW, 3x10mm, Zinc (2) Screw, W/IW, 3x8mm, Chrome (7) Label, Warning, Ozone Label, Laser Registration Label, Rating, 115V Label, Rating, 235V Screw, TPH, 3x6mm, Chrome Vendor Part No. Printronix Part No. 202121001 704539119 202117551 704539048 202122001 704539120 200753001 200754001 200755001 030130306 202123001 202124001 200471001 200470001 030130308 030130310 030231308 200758001 202502001 202503001 202504001 030130306
704539121 704539122
703068001 704831001 704833001
122
18 2 17 1 6 Ref 12 1 19 2 7 1 8 1 9 2 10 1 21 1 20 1 13 1 11 1 9 1 25 1
19 3
2 1 19 1
4 1 3 1 19 1 22 1 23 1
5 1
Covers
123
12.1 Covers Parts List (continued)

Callout 14 15 21 Name Cover, Hinge, Left Cover, Hinge, Right Label, Class 1 Vendor Part No. Printronix Part No. 202119001 704539116 202120001 704539117 201394001
124
15 1 21 1
14 1
Hinge Covers
125
12.2 Left Side Frame Parts List

Callout 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Name Frame, Left Side Frame Assembly, Left Shaft, Waste Toner Container Lever Shaft, Paper Brush Lever, Left Shaft, Developer Clamp Shaft, Safety Lever Side Frame, Left Clamp, Developer Clamshell Latch, Left Spring, Extension, Clamshell Latch Lever, Safety, Left Spring, Torsion, Safety Lever Board Assembly, Sensor, Toner Contact, Toner Sensor (2) Lever, Sensor, Waste Toner Container Screw, PPH, CLFW, 3x6mm, Zinc E-Ring, 5mm I.D., Zinc (2) Cable, Toner Sensor E-Ring, 4mm I.D., Zinc CE Ring, 5mm I.D., Zinc Label, Warning, High Voltage Screw, PPH, CLFW, 3x10mm, Zinc (3) Label, Hi-Pot Test Vendor Part No. Printronix Part No. 200468552 703113001
200512001 200513001 200514001 200516001 200515001 202115551 200517001 030130306 071151008 202393551 071151006 072151008 200815001 030130310 202398001
702714001 702715001 702716001 702718001 702717001 702711001 702719001
704539045
702798001
126
10 1 21 1 1 Ref 2 Ref 4 1 22 1 9 1 17 1 6 1 17 1
11 1
High Voltage Warning Label
20 1
8 1
12 1
14 2 23 1 22 1
18 1
22 1
5 1 7 1 3 1
13 1 15 1 19 1 16 1
Left Side Frame
127
12.3 Right Side Frame Parts List

Callout 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 14 17 Name Vendor Part No. Printronix Part No. Frame, Right Side Frame Assembly, Right 200469551 703112001 Shaft, Safety Lever Shaft, Paper Brush Lever Shaft, Developer Clamp Shaft, Clamshell Latch, Right Side Frame, Right Clamshell Latch, Right 200623001 702763001 Spring, Extension, Clamshell Latch 200514001 702716001 Clamp, Developer 200512001 702714001 Lever, Safety, Right 200621001 702761001 Spring, Torsion, Safety Lever 200515001 702717001 Spring, Grounding, OPC Drum 200622001 702762001 Screw, PPH, CLFW, 3x6, Zinc 030130306 (Screw used to mount OPC Grounding Spring to Frame) E-Ring, 5mm I.D., Zinc (2) 071151008 CE-Ring, 5mm I.D., Zinc 072151008 Screw, PPH, CLFW, 3x6mm, Zinc 030130306 (Screw used to mount OPC Grounding Spring to Base Plate) Screw, PPH, CLFW, 3x10mm, Zinc (5) 030130310 (Screw used to mount Frame to Base Plate)
128
8 1 15 1 1 Ref 2 Ref 9 1 17 1 5 1 10 1 3 1 4 1 6 1 13 1
17 1
16 1
17 2
15 1 7 1
12 1
14 2
11 1 17 1
Right Side Frame
129
12.4 Base Frame Parts List

Callout 1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 13 14 15 16 17 18 19 Name Base Frame Assembly Frame, Main Base Rubber Foot (4) Bracket, Board Support Bracket, Base Frame, Inner Bracket, Backplane Support Bracket, Rear EMI Guide Rail, PCB (2) Frame (Bracket), Floppy Disk Drive Guide (Bezel), Floppy Disk Drive Backplane Board Clamp, Mounted, Wire Harness Screw, PPH, 3x6mm, Zinc (14) Label, CSA Engine Controller Board Grounding Contact (EMI Tab), Backplane Board (3) Screw, PPH, 3x6mm, Zinc (12) Wire Harness, HVPS and Tractor Base Plate Bracket, Display Mounting Wire Harness, Fuser Signal Clamp, Wire Harness, Fuser Signal Cable, LCD Control Panel Vendor Part No. Printronix Part No. 202279001 200492001 202280001 202281001 202282001 202283001 202284001 202286001 202287002 202289551 202290001 030130306 202214001 202505551 202506001 030130306 202291551 202285001 200603001 202296551 202297001 201153001
702698001
704539104 704539106 704539103 704539118 704539107
704539108 704539105
704539038
1210
14 1
17 1
NOTE:
13 1 18 1
Arrows show attachment screw positions
15 1 16 1 19 1 1 Ref 12 1 8 2 4 1 7 1
6 1 21 3
5 1
11 1
9 1 2 1
3 4 10 1
Base Frame
1211
12.5 Overview
This section deals with parts not included in any other sections and includes: S Covers, Ozone Filter Case, and Rating Labels S Left Side Frame S Right Side Frame S Base Frame S Backplane Board
1212
12.6 Left Side Frame 12.6.1 Removal and Disassembly

1. Open the Clamshell and the Front Cover, remove the OPC Drum Unit, the Developer Unit the Waste Toner Container, and any paper present in the printer. 2. Remove the Left Side Cover of the printer. See Figure 121. a. Remove 2 Screws from the Left Side Cover. b. Loosen, but do not remove, 1 Screw on the Base Plate. This loosens the Mounting Bracket so it can be slid free of the Base Plate. c. Lift the front edge of the Left Side Cover to disengage the Locking Tabs, then slide the Cover toward the rear of the printer to disengage the Bracket from the Screw in the Base Plate.
Step 2b Step 2a
Locking Tabs
Figure 121. Removing the Left Side Cover

1213
3. Remove the Front Plastic Paper Guide of the Transfer Charger Assembly by pressing down on its ends and sliding it to the left. This disengages the Locking Tabs and the Guide can be easily removed. See Figure 122.
Figure 122. Removing the Front Plastic Paper Guide 4. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the printer by lifting the rear out first. This helps it clear the Contacts for the HVPS and the Transfer Charger Frame. Disengage the Locking Tabs at the front of the Guide from the Tension Roller Frame. See Figure 123.
1214
Step 4
Detail 121
Step 5
Step 6
Figure 123. Removing the Lower Paper Guide and Encoder Cover 5. Remove 1 Screw, then remove the Encoder Cover. See Figure 123. 6. Release the left side of the Printer Front Cover from the Tab on the Left Side Frame. See Figure 123. CAUTION: Be careful not to break the right side of the Cover where it is connected to the LCD Panel.
7. Disconnect the Cable from Connector J1 of the Toner Sensor Board. See Figure 124.
1215
Disassembly Step 2
High Voltage Warning Label
Disassembly Step 5
Disassembly Step 1
Step 7
Step 8 Disassembly Step 3 Disassembly Step 4
Figure 124. Removing the Left Side Frame 8. Remove 3 Screws from the Left Side Frame and carefully remove it from the printer. See Figure 124. CAUTION: The Cable must be removed carefully from behind the Board as the Frame is being removed from the printer.
DISASSEMBLY
NOTE: The following components can be removed from the Left Side Frame without it being removed from the printer, therefore the following directions assume you have not removed the Left Side Frame from the printer.
1216
1. Remove the Safety Lever Spring, being careful not to damage it, then remove 1 E-ring and remove the Safety Lever. See Figure 124. NOTE: The curved end of the Safety Spring goes toward the Frame; the straight end goes toward the Lever.
2. Remove the Clamshell Latch Spring, then remove 1 E-ring and remove the Clamshell Latch. See Figure 124. 3. Remove 1 E-ring, then remove the Waste Toner Container Lever. 4. Remove 1 Screw, then remove the Toner Sensor Board. 5. Remove 1 CE-ring, then remove the Developer Clamp.

12.6.3 Adjustment
No adjustment of the Left Side Frame is necessary.
1217
12.7 Right Side Frame 12.7.1 Removal and Disassembly

1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, and any paper present in the printer. 2. Open the Printer Front Cover, then remove the LCD Control Panel by removing 2 Screws. Remove the Front Cover by releasing the left side first, then sliding it to the right. See Figure 125.
Detail 122
Step 3
Step 2
Figure 125. Removing the LCD Control Panel 3. Remove the Right Side Cover by removing 3 Screws. See Figure 125.
1218
4. Remove the Lamp Connector cover by removing 1 Screw. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Figure 126.
Step 4
Lamp Connector Cover
Step 5
Right Inside Cover
Figure 126. Disconnecting the Lamp and Thermistor Connectors
1219
5. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Figure 126. NOTE: Upon installation, the groove on the bottom of the Right Inside Cover should straddle the top edge of the right side of the Tractor Frame. See Detail 122 in Figure 125 on page 1218.
6. Remove 2 Screws from the Ozone Filter Case and remove it from the printer. See Figure 125 on page 1218. 7. Remove the Display Mounting Bracket by removing 2 Screws. The Cable Grounding Screw does not need to be removed. See Figure 127. 8. Remove 3 Screws from the Stepper Motor Board Frame, but do not remove any Cables from the Frame. This will allow the Frame to be moved in order to remove the Gear Assembly from the printer See Figure 127.
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12.71.1, Step 9
12.7.1, Step 8
12.7.1, Step 10
12.7.1, Step 10
12.7.1, Step 7
Figure 127. Removing the Display Mounting Bracket
1221
9. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Remove the Frame Cover, and disconnect the Gear Assembly Stepper Motor Cable from the Motor. See Figure 127. 10. Remove 4 Screws from the Gear Assembly Frame then remove it from the printer. The Stepper Motor Board Frame will need to be moved in order to free the Gear Assembly from behind it. See Figure 127. 11. Remove the Front Plastic Paper Guide of the Transfer Charger Assembly by pressing down on its ends and sliding it to the left. This disengages the Locking Tabs and the Guide can be easily removed. See Figure 128.
1222
12.7.1, Step 13
12.7.1, Step 12
12.7.1, Step 11
12.7.1, Step 12
Figure 128. Removing the Transfer Charger Assembly
1223
12. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the printer by lifting the rear out first. This helps it clear the Contacts for the HVPS and the Transfer Charger Frame. Disengage the Locking Tabs at the front of the Guide from the Tension Roller Frame. See Figure 128. 13. Remove the Transfer Charger Paper Guide by gently pressing the Release Tabs at the rear of the Guide toward the front of the printer. Lift the rear of the Guide to clear the Tabs of the slots, and release the Front Tabs by rotating the Guide toward the front of the printer. See Figure 128. 14. Remove the Screw for the OPC Grounding Spring from the Base of the printer, but leave the Screw that connects it to the Right Side Frame attached. See Figure 129. 15. Remove 3 Screws from the Right Side Frame and carefully remove it from the printer. See Figure 129.
1224
Disassembly Step 3
Disassembly Step 5
Step 15
Disassembly Step 4
Step 14
Step 15
Disassembly Step 2
Figure 129. Removing the Right Side Frame
1225
DISASSEMBLY
NOTE: The following components can be removed from the Right Side Frame without it being removed from the printer, therefore the following directions assume you have not removed the Right Side Frame from the printer. The Display Mounting Bracket must be removed in order for the components in Steps 1 through 3 below to be removed.
1. Remove the Display Mounting Bracket by performing Steps 1 through 7 listed above. 2. Remove the Safety Lever Spring, being careful not to damage it, then remove 1 E-ring and remove the Safety Lever. See Figure 129. NOTE: The curved end of the Safety Spring goes toward the Frame; the straight end goes toward the Lever.
3. Remove the Clamshell Latch Spring, then remove 1 E-ring and remove the Clamshell Latch. See Figure 129. 4. Remove 1 CE-ring, then remove the Developer Clamp from the inside of the Frame. See Figure 129. 5. Remove 1 Screw from the Side Frame, then remove the OPC Grounding Spring. See Figure 129.

12.7.3 Adjustment
No adjustment of the Right Side Frame is necessary.
1226
12.8 Base Frame 12.8.1 Removal and Disassembly

1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, the Waste Toner Container, and any paper present in the printer. 2. Remove the Lamp Connector cover by removing 1 Screw. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Figure 1210. 3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Figure 1210. NOTE: Upon installation, the groove on the bottom of the Right Inside Cover should straddle the top edge of the right side of the Tractor Frame.
4. Separate the Fuser Lamp Connector and the Thermistor Connector of the LVPS from the Stepper Motor Board Frame by releasing the Connector Locking Tabs and pushing the Connectors through the hole in the Printer Base Plate. See Figure 1210. 5. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board. Slide the Board out part way, then disconnect the Floppy Disk Drive data and power connectors from the board. Slide the Data Controller Board out the rest of the way and remove it from the printer.
1227
Step 2
Lamp Connector Cover
Step 4
Step 3
Right Inside Cover
Figure 1210. Disconnecting the Lamp and Thermistor Connectors
1228
6. Place the printer on a phone book or other similar item so that the Bottom Cover edges are not resting on the item. Press gently to release the 2 Locking Tabs on the right side of the Bottom Cover, then gently lower this side. Slide the Bottom Cover slightly to the right to release the locking tabs on the left side, then lower the Bottom Cover away from the printer and over the phone book. See Figure 1211.
Figure 1211. Bottom Cover Removal 7. Remove the printer from the phone book. Remove the Screw from the left side of the Base Frame that secures the Engine Controller Board. 8. Unplug the Engine Controller Board from the Backplane Board and remove the Engine Controller Board from the printer through the opening in the rear of the printer. 9. Disconnect 10 Cables from the front of the Backplane Board and 2 Cables from the front of the LVPS. See Figure 1212. NOTE: When reinstalling the Base Frame, refer to Table 121 on page 1251 and Figure 1229 on page 1252 for the proper cable connections to the Backplane Board.
1229
Figure 1212. Removing Cables
1230
10. Remove 2 Screws from the rear of the Base Frame, then lift the LVPS slightly to clear the Base Frame (1). Push the Power Switch to the OFF position (2), then slide the LVPS toward the rear of the printer (3). Use care to avoid damaging the Power Switch. Once the Power Switch is partially past the Frame, switch it to the ON position (4), then slide the LVPS free of the Base Frame (5). See Figure 1213. CAUTION: Use care to avoid damaging the Fuser Lamp Connector. Ensure that it does not catch on the Base Plate. When reinstalling the Lamp, be sure that you route the Fuser Lamp Connector through the Base Plate before you install the LVPS into the Base Frame. See Figure 1214. When installing the LVPS, ensure that the bottom front of the Supply is locked under the Locking Tabs on the Base Frame. See Figure 1215.
NOTE:
1231
1232
Cable Routing
1233
Figure 1215. LVPS Locking Tabs 11. Remove the Floppy Disk Drive (FDD) Guide (Bezel) by pressing on the Locking Tabs, then rotating it to free the bottom tabs. 12. Remove 3 Screws from the front of the Backplane Board. See Figure 1216. 13. Lift the Backplane Board slightly to free it from the Locating Tabs, then tilt it forward so that the top clears the FDD Frame. Now lift the Backplane Board up to free the bottom edge of the Board from the Base Frame. See Figure 1216. NOTE: When installing the Backplane Board, ensure that the rear is inserted into the Board Mounting Bracket. The bottom edge of the Backplane Board must be inserted between the Locating Tabs. See Figure 1216.
1234
Backplane Board is positioned in front of cross brace and behind locating tabs
Figure 1216. Backplane Board Removal and Installation 14. Remove 2 Screws from the front and 1 Screw from the left side of the FDD Frame, then remove the FDD Frame from the Base Frame. See Figure 1217. 15. Remove 2 Screws, then remove the Backplane Support Bracket. See Figure 1217. 16. Remove 2 Screws, then remove the Rear EMI Bracket. See Figure 1217.
1235
Step 14,
FDD Frame
Step 16, Rear EMI Bracket
Step 15, Backplane Support Bracket
Figure 1217. Removing the Base Frame Hardware NOTE: The components listed below must be removed, in addition to those listed above, before the Base Frame can be removed. In order to remove the Base Frame, most of the components on the top of the Base Plate must be removed. Therefore, it is advisable that the Base Frame be removed only in cases where it has been severely damaged and no other options are available.
17. Remove the Fuser Heat Shield. See Figure 1218.
1236
Step 17
W ARNING HIGH TEMPERA T U R E
Step 21
PLEASE REFET A T L PLA SAMTICE CLEANE MER AT O E S N E R.
Step 20 Depress white retaining levers to release fuser roller assembly from fuser base Step 22 J1 Connector Step 18 Step 25
Step 24
Step 23
Figure 1218. Removing Various Parts
1237
18. Remove the Tractor Paper Guide by removing 1 Screw from the center rear of the Tractor Frame. See Figure 1218. 19. Open the Paper Exit Guide of the Fuser Base so that it is not in contact with the Fuser Roller Assembly. 20. Depress the Fuser Roller Retaining Lever on each side of the printer so that the Fuser Roller Assembly is free to move. See Figure 1218. 21. Lift the Fuser Roller Assembly free of the Fuser Base, then remove it from the printer. See Figure 1218. 22. Disconnect the Fuser Sensor Board by removing the Cable at Connector J1. See Figure 1218. 23. Open the Printer Front Cover, then remove the LCD Control Panel by removing 2 Screws. See Figure 1218. 24. Remove the Right Side Cover by removing 3 Screws. See Figure 1218. 25. Remove 2 Screws from the rear of the Fuser Base and remove it from the printer. See Figure 1218. 26. Remove 2 Screws from the Ozone Filter Case and remove it from the printer. See Figure 1219.
1238
Step 26
Step 27
Figure 1219. Removing the Ozone Filter Case and Stepper Motor Board Frame 27. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Remove the Frame Cover and disconnect 7 Cables from the board (CN1, CN2, CN3, CN4, CN5, CN6, and CN8). See Figure 1219 and Figure 1220.
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CN3
CN4
CN5
CN1
CN2
CN8
CN7
CN6
Figure 1220. Stepper Motors Controller Board Connector Identification 28. Remove the Tractor Paper Guide by removing 1 Screw. Disconnect the Cable from the Fuser. Remove 1 Screw from the Cable Tie to release the Cable from the Base Plate of the printer. See Figure 1221. 29. Remove 2 Screws from the Stepper Motor Board Frame and remove it from the printer. See Figure 1221. 30. Remove 2 Screws from the rear corners of the Base Plate. See Figure 1221. 31. Remove 3 Screws from the right side of the Base Plate. See Figure 1221.
1240
Step 30
Step 40 Step 39
Step 29
Step 31
Step 42
Note: arrows show attachment screw positions
Step 44 Step 43
Figure 1221. Removing Various Components
1241
32. Remove the Left Side Cover of the printer. See Figure 1222. a. Remove 2 Screws from the Left Side Cover. b. Loosen, but do not remove, 1 Screw on the Base Plate. This loosens the Mounting Bracket so it can be slid free of the Base Plate. c. Lift the front edge of the Cover to disengage the Locking Tabs, then slide the Cover toward the rear of the printer to disengage the Bracket from the Screw in the Base Plate. Step 32b Step 32a
Locking Tabs
Figure 1222. Removing the Left Side Cover 33. Remove the Front Plastic Paper Guide of the Transfer Charger Assembly by pressing down on its ends and sliding it to the left. This disengages the Locking Tabs and the Guide can be easily removed. See Figure 1223.
1242
Figure 1223. Removing the Front Plastic Paper Guide 34. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the printer by lifting the rear out first. This helps it clear the Contacts for the HVPS and the Transfer Charger Frame. Disengage the Locking Tabs at the front of the Guide from the Tension Roller Frame. See Figure 1224. 35. Remove 1 Screw, then remove the Encoder Cover. See Figure 1224. 36. Release the left side of the Printer Front Cover from the Tab on the Left Frame and remove the Cover. See Figure 1224.
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Step 34
Step 35
W ARNING HIGH TEMPERA TU RE
PLEASE REFE TA T LPLA SAME CE CLEANTI AS MER T O E NE R.
Step 36
Figure 1224. Removing Paper Guide, Encoder Cover, and Front Cover 37. Disconnect the Cable from Connector J1 of the Toner Sensor Board. See Figure 1225. 38. Remove 3 Screws from the Left Side Frame and carefully remove it from the printer. See Figure 1225. CAUTION: The Cable must be removed carefully from behind the Board as the Frame is being removed from the printer.
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Step 37
J1 Connector
Step 38
Figure 1225. Removing Left Side Frame 39. Remove 1 Screw from the left front corner of the Base Plate. See Figure 1221. 40. Remove the Tractor by removing 3 Screws, then lifting the left end of the Tractor out first. This clears the Encoder of the HVPS, and allows the Tractor room to move to the left so that the Tractor Stepper Motor can clear the Upper Board Frame. See Figure 1221. 41. Disconnect the Cable from the Tractor Stepper Motor and remove the Tractor from the printer. 42. Remove 2 Screws, then remove the Inner Frame Brace. See Figure 1221. 43. Remove 2 Screws from the bottom of the Base Frame. The Inner Frame can now be removed from the Base Frame of the printer. See Figure 1221. 44. Remove 1 Screw from the bottom of the Base Frame, then remove the Board Support Bracket. See Figure 1221.
1245
45. Remove the PCB Guide Rails or Cable Tie from the Base Frame, as needed.

Reverse the steps listed above, as needed. Table 121 on page 1251 lists the connectors on the Backplane Board, together with their respective functions and destinations. Figure 1229 on page 1252 shows the locations of the connectors on the Backplane Board.
12.8.3 Adjustment
No adjustment of the Base Frame is necessary.
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12.9 Backplane Board 12.9.1 Removal and Disassembly

1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, the Waste Toner Container, and any paper present in the printer. 2. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board. Slide the Board out part way, then disconnect the Floppy Disk Drive data and power connectors from the board. Slide the Data Controller Board out the rest of the way and remove it from the printer. 3. Place the printer on a phone book or other similar item so that the Bottom Cover edges are not resting on the item. Press gently to release the 2 Locking Tabs on the right side of the Bottom Cover, then gently lower this side. Slide the Bottom Cover slightly to the right to release the locking tabs on the left side, then lower the Bottom Cover away from the printer and over the phone book. See Figure 1226. 4. Remove the printer from the phone book. Remove the Screw from the left side of the Base Frame that secures the Engine Controller Board. 5. Unplug the Engine Controller Board from the Backplane Board and remove the Engine Controller Board from the printer through the opening in the rear of the printer. 6. Remove the Floppy Disk Drive (FDD) Guide (Bezel) by pressing on the Locking Tabs, then rotating it to free the bottom tabs.
1247
Figure 1226. Bottom Cover Removal 7. Disconnect 10 cables from the front of the Backplane Board. See Figure 1227. NOTE: When reinstalling the Backplane Board, refer to Table 121 on page 1251 and Figure 1229 on page 1252 for the proper cable connections to the board.
1248
Figure 1227. Removing Cables
1249
8. Remove 3 screws from the front of the Backplane Board. See Figure 1228. 9. Lift the Backplane Board slightly to free it from the Locating Tabs, then tilt it forward so that the top clears the FDD Frame. Now lift the Backplane Board up to free the bottom edge of the Board from the Base Frame. See Figure 1228. NOTE: When installing the Backplane Board, ensure that the rear is inserted into the Board Mounting Bracket. The bottom edge of the Backplane Board must be inserted between the Locating Tabs. See Figure 1228.
Backplane Board is positioned in front of cross brace and behind locating tabs
Figure 1228. Backplane Board Removal and Installation
1250

Reverse the steps listed above, as needed. Table 121 below lists the connectors on the Backplane Board, together with their respective functions and destinations. Figure 1229, following, shows the locations of the connectors on the Backplane Board. Table 121. Backplane Board Connectors Connector J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J11 J12 J13 J14 J15 Function Engine Controller Board Interface Data Controller Board Interface LCD Control Panel LSU Cable Fuser Sensor Board Stepper Motor Control Power Input Stepper Motor Board Power Toner Sensor Board HVPS Paper Empty Sensor Not Used Tractor Encoder Board Not Used Not Used Destination Engine Controller Board Data Controller Board LCD Control Panel LSU J1 on Fuser Sensor Board CN2 on Stepper Motors Controller Board CN1 on LVPS CN2 on LVPS J1 on Toner Sensor Board Rear of HVPS Base Plate Not Used Connector In Base Plate Behind Tractor Not Used Not Used
1251
J10 J13 J5 J6 J1 J9 J11 J4 J2 J3 J15 J14 J8 J7
Figure 1229. Backplane Board Connectors
12.9.3 Adjustment
No adjustment of the Backplane Board is necessary.
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Operation Sequence
Knowing the sequence of operation of the printer is useful as a guide in determining what component is at fault for a given failure. Follow the sequence below to the point where the printer fails. This will be a good starting point for further troubleshooting of the printer.
Power-Up Self-Test
When the printers AC power is turned on, the first things that occur are the Engine Controller Board and Data Controller Board self-tests. Each controller board runs its own self-test independently from the other. At the completion of a successful self-test, the Engine Controller sends a PPRDY command to the Data Controller, and the Data Controller returns a CPRDY command to the Engine Controller. These signals tell each board that the other board has passed its self-test and is prepared to communicate. The Engine Controller Board then initiates the engine self-test sequence, as follows: The Engine Controller first verifies that the top cover is closed, then checks the paper jam sensor in the fuser. Next, the Engine Controller checks the paper empty sensor to see if there is paper present in the printer. The erase LEDs and the stepper motor are then turned on, followed by the fuser heater. The developer, OPC drum, and fuser cam motors are all cycled to check for proper operation. While the developer is being cycled, the toner sensor is checked to verify that it is functioning. Once all of these have been verified, the Engine Controller tests the LSU to ensure that it is functioning correctly. The polygon motor, the beam detector, the laser, and the laser power circuitry are all tested in this step. The fuser must reach operating temperature within 2 minutes after it is turned on. After the fuser has reached fusing temperature, the Engine Controller checks for top of form (TOF) registration. If the TOF sensor is tripped by the plastic TOF lever (flag assembly), the Engine Controller will not try to seek TOF. If the sensor is not tripped, the Engine Controller will set TOF by moving paper into the proper position. To set TOF, the stepper motor, electric clutch, and fuser cam motor are all activated. The fuser closes, then the tractor feeds paper into the printer until the paper depresses the TOF lever. The fuser then begins to pull the paper through the printer slightly faster than does the tractor. The Engine Controller monitors the pulses from the tractor encoder wheel to ensure that the paper is moving at the proper speed. If the encoder malfunctions during TOF registration, the paper will move about 1/2 inch before a Paper Jam error occurs. The Engine Controller feeds two sheets of paper into the printer so that the perforation for the next sheet to be printed is aligned with the OPC drum.
Print Command
Once the Data Controller Board has sent a print command to the Engine Controller Board, the printer performs the following steps. If the fuser is below the fusing temperature, the Engine Controller turns on the fuser lamp to heat the fuser. Once the fuser is at the fusing temperature, the Engine Controller turns on the erase LEDs and the stepper motor. Next, the Engine Controller activates the LSU and checks it for proper functioning. This completes the initialization process for the printer. After initialization has been completed, the Engine Controller Board activates the High Voltage Power Supply (HVPS), supplying high voltages where needed throughout the printer. The Engine Controller then closes the fuser and pulls the VSREQ signal to the Data Controller Board low, which asserts Vertical Synchronization Request to the Data Controller. In response, the Data Controller pulls the VSYNC signal
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to the Engine Controller low, which asserts Vertical Synchronization to the Engine Controller. When the Engine Controller detects the asserted Vertical Synchronization signal, it starts the print process. The Engine Controller activates the electric clutch and transfer charger solenoid, and prints the data on the page. The printer will continuously print all of the pages in the print job as long as it continues to receive print commands from the Data Controller. Note that the print command for the next page must be received before the N minus 4th encoder pulse (VLC) of the current page, or the paper will stop between pages.
Checking the Power-up Sequence

To observe the power-up sequence, perform the following steps: 1. Turn off the printer power. 2. Open the top cover and defeat the cover open switch. 3. Turn on the printer power and watch for the following actions: S The erase LEDs will light S The fuser will cycle closed then open S The developer and OPC drum units will cycle S The fuser lamp will begin to heat
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Guide to Imaging Errors Index to Imaging Errors

The following section is an index of common imaging errors. It guides you to the isolation and correction of the errors listed. To use the index, find the error in the index list that appears on the printers LCD, then find that index number in the next section, Detailed Troubleshooting Steps. Using that number, you will be guided in troubleshooting and correction of that particular error. Title 100. Horizontal Image Errors 110. Uniform 1-inch-interval line (indistinct width and fuzzy edges) 120. Black horizontal line (thin with sharp edges) 130. White horizontal line with a 5 inch interval (indistinct width with a tapered shape and fuzzy edges) 140. White horizontal line with a 2.5 inch interval (indistinct width with a tapered shape and fuzzy edges) 150. White horizontal lines with intervals other than that mentioned above 160. Faint black horizontal lines that occur at random 170. No print at the top of the page accompanied by a 1 inch black streak 1.5 inches down the page. 200. Vertical Image Errors 210. Narrow white line (sharp edges) 220. Wide white line (fuzzy edges) 230. Black line (indistinct width with fuzzy edges) 240. Black or white line (sharp, well-defined edges) 250. Wide black line (indistinct edges) 1310 1310 1311 1311 1312 1312 1310 1310 139 139 Page 138 138 138 139
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Title 260. Distorted image running the length of the page 270. The output page is creased 300. Cyclic Image Errors 310. Black area at a 1 inch interval 320. White area at a 2.5 inch interval 330. White or black area at a 3 inch interval 340. Black or white spot at a 5 inch interval 350. Wavy image at far right side of printed page 360. Black or white horizontal streak at a 1.5 inch interval 400. Image Errors at the Same Point on Each Page 410. Fine vertical lines at 1.5 inches from the top perforation 420. Gray or black horizontal line at the perforation of the first page 430. Blurred image on the first line of the first page of a print job 440. Blurred image on the first to third line of the last page of a print job 450. Uneven or light print density across the page 500. Image Errors Over a Large Area 510. No print (blank page) 520. Full or partial black page 530. Dirty background in unprinted areas of the page 540. White or black concentric rings 550. The print area is weak, barely visible
Page 1312 1313 1313 1313 1313 1313 1314 1314 1314 1314 1314 1314
1315
1315
1315 1316 1316 1318 1319 1320 1320
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Title 560. The print has many unexplained seemingly random errors 570. Dirty background accompanied by a ghost image 580. Print is intermittently dark, then goes to light 600. Other Image Errors 610. Vertically blurred image 620. Vertically compressed image 630. Ghost or mirror image 640. Intermittent black patches 650. Black spots on white print or white spots on black print 660. Unfused toner 670. The top half of the first line of a print job is missing 680. Patchy light or dark regions on the page.
Page 1321 1321 1322 1322 1322 1322 1323 1324 1324
1325 1325 1325
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Detailed Troubleshooting Guide

The following section guides you to the cause and repair of the errors found in a printed image. NOTE: Errors that occur on a regularly repeating basis usually are caused by one of the rollers or gears in the printer. The interval of the error is equal to the circumference of the roller or the circumference of the base of the teeth on the gear. The following table lists examples of the most common sources of these errors. These are approximate distances. Table 131. Sources of Repeating Errors Distance Between Repeating Errors 1 inch 1.5 inch 2.5 inch 3 inch 5 inch
Typical Source of the Error The magnetic sleeve inside the developer roller of the Developer Unit The inner transfer gear in the developer gear assembly The guide rollers on the Developer Unit The fuser roller The OPC drum
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Preliminary Steps
By following these two steps, you will pinpoint the source of the problem more quickly and make troubleshooting much easier and faster. 1. Engine Self-Test Running the printer engine self-test can help isolate a problem to the printer engine, the Engine Controller Board, the Data Controller Board, or the host computer. The self-test printout consists of solid vertical lines (feedlines) every 1/16 inch running the entire length of the page and over the full width of the page. a. Press the small button on the Engine Controller Board, accessible through the small round hole in the left side of the plastic Bottom Cover. This prints one test page. If you hold the button in, the printer prints continuously until the button is released. Remember that after you push the button, if the fuser is not up to its normal operating temperature, there might be a delay while the fuser heats, before the printer starts printing. b. If the engine self-test runs with no errors, the Data Controller Board or host computer is probably at fault. Run one of the Data Controller Board printing self-tests. These tests are accessible from the Diagnostics menu, using the Control Panel keys. (Refer to the Setup Guide for instructions on accessing and running these tests.) Running a printing self-test will isolate the error to either the Data Controller Board or the host computer. For further help in troubleshooting Data Controller Board and host computer problems, refer to the Data Controller Board troubleshooting section in Chapter 9, Controllers and Floppy Disk Drives. c. If errors or other problems occur when running the engine self-test, continue with the following steps. 2. Isolation Procedure Using the Engine Self-Test a. Stop a test print in the middle of a page by turning off the printer or opening the top cover. Remove the OPC drum and check to see if the error is showing on the developed image on the OPC drum. Turning off the printer during operation leaves the developed image on the OPC drum. If the printer is allowed to operate until the print cycle is complete, the OPC drum is cleaned and there is no developed image. b. If the error is not apparent in the developed image on the OPC drum, check the unfused page between the OPC drum and the Fuser. If the error is present on the unfused page, the Transfer Charger is the source of the error. If the error is not present on the unfused page, the Fuser is the source of the error. c. If the error appears on the OPC drum, block the laser beam at the LSU cover glass and repeat step 2a above. If the error is still apparent on the OPC drum, the LSU is not the source of the error and the Developer Unit and OPC Drum Unit must be checked. If the error is not on the OPC drum, the LSU is probably the source of the problem. d. If the error is well defined on the OPC drum with the laser beam blocked, the source of the error is most likely the OPC Drum Unit or its power source. e. If the error occurs on a large portion of the page, the OPC Drum Unit, the Developer Unit, or the High Voltage Power Supply (H.V.P.S.) may be the source of the error.
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Detailed Troubleshooting Steps

By following these steps, you will be able to pinpoint the source of the problem and make any necessary corrections needed to fix the problem. 100. 110. Horizontal Image Errors Uniform 1 inch interval line (indistinct width and fuzzy edges). This is best exhibited by printing a black page. 111. The contact between the developer sleeve and the electrode is defective. a. Apply conductive grease to the developer sleeve contact. b. Replace the developer unit. 112. The contact between the developer unit and the H.V.P.S. electrode or spring is defective. a. Make sure there is no corrosion on the spring of the H.V.P.S. contact or on the developer unit contact. b. Make sure the spring is making good physical contact with the contact. The spring can be lengthened by pulling it in order to make better contact. Make sure to pull the spring upward, not at an angle. 113. The bias voltage from the H.V.P.S. is incorrect. a. Check the developer roller bias via the procedure in Chapter 8, Power Supplies, and adjust if needed. b. Replace the H.V.P.S. if the bias cannot be correctly adjusted. 120. Black horizontal line (thin with sharp edges). This is usually caused by a static discharge to the laser. This may be present on a blank page. 121. The ground connection between the paper brush and the printer is faulty. The paper brush builds a static charge that discharges into the laser drive circuitry through the printer base pan. a. Remove the paper brush and check to see if the line is still present when printing. b. Make sure the paper brush is properly seated. c. Make sure the grounding spring on the paper brush is not damaged or corroded. d. Make sure the grounding spring is making good physical contact with the shafts of the paper brushes. e. Replace the paper brush if the above steps do not fix the problem, or if the line is not present in step a. 122. The contact between the transfer charger electrode and the H.V.P.S. contact spring is faulty. This causes discharges (sparks) which cause the laser drive circuitry to turn on the laser when it should not be on.
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a. Loosen the transfer corona assembly and reseat it to make sure it contacts the H.V.P.S. spring. The assembly should lock under the tab on the left side of the transfer charger frame. Slide the assembly to the right as far as possible. b. Make sure the transfer corona electrode and the H.V.P.S. spring are not corroded. c. Make sure the H.V.P.S. contact spring is making good physical contact with the electrode. The spring can be lengthened by pulling (stretching) it. Make sure to pull the spring upward, not at an angle. d. Make sure that there is no toner or paper dust on the corona wire or in the corona wire channel. 130. White horizontal line with a 5 inch interval (indistinct width with a tapered shape and fuzzy edges). The line is narrower in the center of the page. This is best exhibited by printing a black page. 131. There is toner buildup on the OPC drum where the guide roller of the developer contacts the OPC drum. a. Check for toner buildup on the side of the OPC drum where the stripe is occurring. Clean the toner from the drum. Avoid scratching the drum. b. Replace the OPC drum unit. 132. The OPC drum has an area on it that has poor electrical characteristics. a. Replace the OPC drum unit. 140. White horizontal line with a 2.5 inch interval (indistinct width with a tapered shape and fuzzy edges). The line is narrower in the center of the page. This is best exhibited by printing a black page. 141. There is toner buildup on the guide roller of the developer unit. This will be on the same side of the developer where the line is occurring on the page. a. Clean the toner from the guide roller. 142. The guide roller has been worn and is no longer round. a. Replace the developer unit. 150. White or black horizontal lines with intervals other than those mentioned above. These lines have an indistinct width and fuzzy edges. These are best exhibited by printing a black page. These errors usually will be caused by a defect in one of the gears in the developer gear assembly. A problem with a gear in the main gear assembly can cause an image error, but it should be accompanied by Paper Jam errors.
139
The defect could be a broken or damaged tooth, or it could be toner buildup in the base of the teeth on a gear. The pitch or interval of the error is equal to the circumference of the gear, or the circumference of the base of the teeth. The approximate diameter of the gear can be found by using the equation
c d+p
where d is the diameter of the gear, c is the interval of the error, which is equal to the circumference of the gear, and p = 3.14. This will give you a general idea of the size of the gear at fault. 151. White or black horizontal line with an interval of 1.5 inches. a. This is usually caused by the inner transfer gear in the developer gear assembly. The gear breaks at its shaft and tends to slip. Remove the developer gear assembly and replace the inner transfer gear. 152. White or black horizontal lines with a repeating interval. a. Find the approximate diameter of the defective gear as shown above and replace the gear or its associated assembly. 153. Occasional white streak at an inconsistent interval. a. The drive gear for the developer gear assembly is broken at the point where it connects to the shaft. Replace the gear with one that has reinforcing ribs. 160. 161. Faint black horizontal lines occur at random. The plastic paper guide on the transfer charger is not installed correctly. Make sure it is locked down by sliding it to the right. There is no print at the top of the page accompanied by a 1 inch black streak 1.5 inches down the page. The streak may repeat 5 inches down from the original streak. The OPC drum ground connection is faulty, and the OPC drum cleaning system cannot remove the residual toner from the drum. The erase LEDs cannot reduce the drum potential to 0 volts. a. Check the OPC drum ground spring and replace it if needed. b. Replace the OPC drum unit. 172. The cleaning brush/tension roller does not have the correct voltage. a. Check and lengthen the spring contact if needed. b. Replace the OPC drum as its contact for the cleaning station is defective. c. Check and replace the H.V.P.S. if needed. 200. 210. Vertical Image Errors. Narrow white line (sharp edges). This line is not present when the laser beam is blocked at the LSU cover glass.
170.
171.
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211.
The laser beam is being blocked and is not reaching the OPC drum. a. Check the LSU cover glass and clean if necessary. b. Replace the cover glass if it is cracked or cannot be cleaned. c. The LSU has something blocking the beam inside it and must be replaced. The LSU cannot be opened and cleaned, it must be replaced.
212.
There is a foreign object behind the doctor blade in the developer unit that is preventing the toner from reaching the developer sleeve. To verify this, examine the developer sleeve. Look for a line of missing toner. a. Replace the developer unit.
213.
The OPC drum has a defect in it that extends completely around its circumference. a. The OPC drum has a scratch and must be replaced. b. The OPC drum has an area of poor electrical characteristics and it must be replaced.
214.
If the streak does not appear on the OPC drum, there is a foreign object that is rubbing on the unfused page. a. Locate and remove the obstruction in the paper path that is somewhere between the transfer charger and the fuser. This is usually a piece of paper that is touching the paper and smearing the unfused toner. This is usually at the entrance to the fuser.
215.
There is something on the transfer corona wire or in the corona wire channel. a. Clean any toner from the corona wire with the corona cleaning felt. b. Remove any paper in the transfer charger channel.
220. 221.
Wide white line (fuzzy edges). The printer has been operated with a low toner condition, resulting in an area of light print. This can be seen by looking at the developer sleeve in the developer unit. If it appears gray instead of black, the toner is low. a. Replace the toner cartridge on the developer unit. b. The carrier has been depleted from the developer by printing with a low toner condition. Replace the developer unit with a new one that has been charged recently with new carrier. c. The OPC drum has been damaged by carrier on its surface and must be replaced.
222.
There is something on the transfer corona wire or in the corona wire channel. a. Clean any toner from the corona wire with the corona cleaning felt. b. Remove any paper in the corona wire channel.
230.
Black line (indistinct width with fuzzy edges). This line will still be present when the printer is operated with the laser beam blocked at the LSU cover glass.
231.
The OPC drum is not being charged correctly.
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a. Check and clean the charge corona wire and grid. b. Make sure the contact between the OPC drum unit and the contact spring for the charge corona is good. 1. Clean any corrosion from the contact and the spring. 2. Stretch the spring by pulling the end of it if the spring is compressed and the contact is still poor. Make sure to pull the spring upward, not at an angle. c. Check the charge current from the H.V.P.S. according to the procedure in Chapter 8, Power Supplies, and adjust the H.V.P.S. if necessary. 1. Replace H.V.P.S. if the charge current cannot be adjusted correctly. 240. 241. Black or white line (sharp well defined edges). The OPC drum has been scratched. This scratch will extend around the circumference of the drum. a. Replace the OPC drum unit. 242. The OPC drum has an area of poor electrical characteristics and it must be replaced. a. Replace the OPC drum unit. 243. There is a scratch or toner buildup around the circumference of the fuser roller. a. Replace the fuser roller. 250. Wide black line (indistinct edges). This line is not present when the laser beam is blocked at the cover glass. 251. Verify that the Engine Controller Board is set to the correct resolution. a. Check jumper J1 on the Engine Controller Board to verify correct resolution. It should be present for 240 dpi operation and should be removed for 300 dpi operation. 252. The LSU is out of alignment and the laser beam is reflecting from a surface it should not be striking. This is occurring inside the LSU. a. Replace the LSU. 53. The laser is being turned on too soon or turned off too late. This causes reflections inside the LSU that strike the OPC drum. a. Replace the Engine Controller Board. b. Replace the LSU. 260. 261. Distorted or blurred image running the length of the page. There is something on the LSU cover glass that is causing the laser beam to be distorted. a. Clean the cover glass and replace it if necessary. 262. There is something on the optics inside the LSU.
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a. Replace the LSU. 270. 271. The output page is creased. There is a crease running down the center of the output page. a. Adjust the fuser rear cover position. The cover is too close to the pressure roller. b. Replace the fuser if the rear cover is damaged or cannot be properly adjusted. 272. There are creases throughout the output page. a. Adjust the fuser rear cover position. The cover is too close to the pressure roller. b. Replace the fuser if the rear cover is damaged or cannot be properly adjusted. 300. 310. 311. Cyclic Image Errors. Black area at a 1 inch interval. The doctor blade gap is too large, causing excess toner to build up, which causes blocking. This will be evident by a severe grinding noise in the printer. a. Replace the developer unit. 312. The contact between the developer sleeve and the electrode is faulty. a. Apply conductive grease to the developer sleeve contact. b. Replace the developer unit. 313. The contact between the developer unit and the H.V.P.S. is faulty. a. Make sure there is no corrosion on the spring of the H.V.P.S. contact or on the developer unit contact. b. Make sure the spring is making good physical contact with the contact. The spring can be lengthened by pulling it in order to make better contact. 314. The bias voltage from the H.V.P.S. is incorrect. a. Check the developer roller bias according to the procedure in Chapter 8, Power Supplies, and adjust if needed. b. Replace the H.V.P.S. if the bias cannot be adjusted correctly. 320. 321. White area at a 2.5 inch interval. There is toner buildup on the guide roller of the developer unit. a. Clean the toner from the guide roller. b. Replace the developer unit. 322. The guide roller has been worn and is no longer round. a. Replace the developer unit. 330. Black or white area at a 3 inch interval.
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331.
This is caused by a defect or toner buildup on the fuser roller. a. Clean or replace the fuser roller/fuser assembly.
340. 341.
Black or white spot at a 5 inch interval. The OPC drum has a scratch or nick on it. a. Replace the OPC drum unit.
342.
There is toner buildup on the OPC drum where the guide roller of the developer contacts the OPC drum. a. Check for toner buildup on the OPC drum. Clean the toner from the drum. This will be located on the outside ends of the drum where there is no green coating. b. Replace the OPC drum unit.
343.
The OPC drum has an area on it that has poor electrical characteristics. a. Replace the OPC drum unit.
350. 351.
Wavy image at the far right side of the printed page. The phase-locked loop (PLL) of the LSU polygon motor is not staying locked.
This results in the speed of the polygon motor changing, which causes the length of a printed line to change. If this becomes severe, an LSU FAIL error will occur. a. Replace the LSU. 352. The polygon is not attached securely to the polygon motor spindle. a. The LSU must be replaced. The adhesive that holds the polygon mirror to the spindle is defective. 360. 361. Black or white horizontal streaks at 1.5 inch intervals. The inner transfer gear has broken where it attaches to the main drive gear. This is in the developer gear assembly. a. Replace the inner transfer gear. 400. 410. Image Errors Occurring At The Same Place On Each Page. Fine vertical lines at 1.5 inches from the perforation at the top of the page.
This occurs when the printer has been inactive for some period of time. 411. The silicon/toner on the fuser wiper migrates from the wiper onto the fuser roller and paper. This occurs when the fuser wiper is saturated with toner. a. Replace the fuser wiper. b. Replace the fuser roller if it is damaged. 420. Gray or black horizontal line at the perforation on the first page of a print job.
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This is caused by the paper touching the OPC drum. 421. The paper pressure plate is not functioning properly. a. Make sure the paper pressure plate is properly installed. b. Make sure the mylar sheet is not damaged and is making good physical contact with the paper. c. Make sure the paper pressure plate spring is functioning correctly. The plate should be spring loaded so that it pushes the paper down away from the OPC drum. 422. The transfer charger is rising too high when it engages. a. Make sure the dampers on the transfer charger are not missing or excessively worn. b. Make sure the transfer charger is not engaging or rising before the paper starts to move. 1) The engagement lever might be bent and not pulling the charger down enough when the fuser closes. Replace the lever. 423. The paper stock being printed is too heavy and is touching the OPC drum when the transfer charger is engaged during printing. a. Use a lighter stock paper during printing. 424. The paper stock is folding as it enters the printer. a. The paper brush is not installed in the printer. Replace the paper brush. 430. 431. Blurred image on the first line of the first page of a print job. The transfer charger bounces when it reaches its uppermost position. It strikes the paper causing the toner to scatter. a. The dampers on the transfer charger are missing. This condition produces a loud noise when the charger engages. Replace the transfer charger. b. The transfer charger is worn and needs to be replaced. 440. Blurred image on the first to third line of the last page of a print job. Under normal printing conditions, the last page of a print job is not fed through the fuser. 441. The last page of the print job has not been fused, and is still in the printer. The fuser melts the toner of the first few lines on the page. a. As soon as the print job finishes, perform a form feed to fuse the last page. b. At the end of each print job, print a blank page or include a form feed in the commands from the host to the printer. 450. 451. Uneven or light print density across the page. The gap between the developer sleeve and the OPC drum is too big. This results in uneven toner transfer from the sleeve to the drum.
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a. The developer unit is not locked down. Verify that the developer lock down hooks are properly engaged. There is usually excessive gear noise or grinding noise when the developer is not locked down. b. There is toner buildup on the developer guide roller or on the OPC drum where the guide roller meets the OPC drum. Clean the toner buildup from the appropriate area. 452. The printer is being operated with low toner. a. Install a new toner cartridge on the developer unit. b. If the toner no longer adheres to the developer sleeve or the print is still light, replace the developer. Prolonged operation of the developer with low toner depletes the carrier at a faster rate than normal. The developer will no longer be able to print 100,000 pages. 453. The paper is skewing as it enters the printer. a. Make sure the paper source is properly aligned with the printer so that the paper is not skewing as it enters the printer. 454. The main drive gear for the developer gear assembly is broken.
This causes the developer sleeve to slip and not rotate properly. This can be checked by manually removing an area of toner from the developer sleeve. Operate the printer for a couple of pages, then check the sleeve. The sleeve should no longer have the area of no toner on it. If the area of no toner is still present, the developer main drive gear is broken and the developer sleeve is not turning. a. Verify that the gear is broken and replace it with a gear that has been reinforced with ribs. If the gear is not broken, but does not have reinforcing ribs, it should be replaced with a gear that has been reinforced with ribs. 500. Image errors over a large area of the page.
Note that it is very important to follow the isolation procedure described at the start of this guide. There are a number of different causes for these failures, and troubleshooting is much easier if the isolation procedure is followed. 510. No print (blank page).
Follow the steps below if there is a developed image on the OPC drum: 511. The transfer charger is not rising into position. a. Make sure the engagement lever is not binding on the transfer charger. Make sure the lever moves freely. b. Make sure the engagement lever roller is properly seated on the engagement cam lever of the fuser. c. The transfer solenoid is not engaging correctly. Check to make sure the signal to release the solenoid is being sent from the L.V.P.S. 1. If the signal is present, replace the transfer solenoid.
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2. If there is no signal, replace the L.V.P.S. A. If the solenoid still does not function after replacing the L.V.P.S., replace the Engine Controller Board. d. The transfer charger is not moving freely and must be replaced. 512. There is no charge on the transfer corona. a. Make sure the transfer corona wire is not broken. b. Make sure the contact between the H.V.P.S. and the transfer corona is good. 1. Clean toner or paper dust from the transfer corona contact and the H.V.P.S. spring. 2. Clean off any corrosion on the transfer corona contact. 3. If the spring for the H.V.P.S. contact is compressed, lengthen it by pulling the top of it. This helps ensure gooid electrical contact. Make sure to pull the spring upward, not at an angle. c. Check the charge from the H.V.P.S. according to the procedure in Chapter 8, Power Supplies, and replace the power supply if the charge is not present. d. If the charge is not present after step c, replace the L.V.P.S. e. If the charge is not present after step d, replace the Engine Controller Board. f. If there is still no charge present, check all wire harnesses. Follow the steps below if there is no developed image on the OPC drum: 513. The OPC drum has the proper charge, but is not discharging properly. a. The OPC drum is no longer sensitive to light and is not discharging when the laser beam strikes it. Replace the OPC drum. This usually occurs after the OPC drum unit has been in the printer for quite some time. This can also be caused by the OPC drum being exposed to light for a prolonged period of time. Check the drum count to see how many pages have been printed with the OPC drum. Replace the drum if the count exceeds 30,000 pages. b. The OPC drum unit is not properly grounded. Make sure the OPC drum grounding spring is not damaged. It must also make good physical contact with the printer base pan. 514. The main drive gear for the developer gear assembly is broken. a. The drive gear is broken and is not turning the developer sleeve. Replace the gear with one that has reinforcing ribs. 515. The H.V.P.S. contact spring for the developer unit has no charge. a. Check the contact spring from the H.V.P.S. according to the procedure in Chapter 8, Power Supplies. If there is no charge, replace the power supply. b. If there is no charge present with the new H.V.P.S., replace the L.V.P.S. c. If both power supplies have been replaced, replace the Engine Controller Board.
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d. If there is no charge after step c, check all wire harnesses. 516. The developer contact spring has the proper charge on it. a. Make sure there is good contact between the spring and the developer unit. Clean off all corrosion on the spring and on the contact. Lengthen the spring, if compressed, by pulling it. Make sure to pull the spring upward, not at an angle. b. Make sure the developer unit has toner in it. c. The developer unit is defective and must be replaced. 517. The LSU is not aligned properly and the laser beam is not exiting from the LSU cover glass. (If the laser itself were not working, a BEAM DET FAIL error or an LSU FAIL error would occur.) The LSU could become misaligned if the printer were dropped or severely jarred. This would be a very rare instance. a. Replace the LSU. Follow the next step if there is print on the page with the engine self-test, but not when printing from the host computer: 518. The host computer is not properly connected to the printer, or is not properly configured for the printer. a. Verify the cabling from the printer to the computer. b. Verify the software configuration for the printer. Follow the next step if there is no print when running a self-test from the Control Panel or if a print job does not print from the computer. The engine self-test works properly, and step 518 has been completed. 519. The Data Controller Board is not functioning properly. a. Replace the Data Controller Board. 520. Full or partial black page. Partial areas of black on a page usually indicate static discharges. Check any source of static along the paper path, as this is the most common source of static in the printer. Full pages of black print usually indicate a missing charge voltage or a damaged laser. Follow these steps when the page is partially covered with black print: 521. The paper brush is not properly grounded, causing a static discharge to turn on the laser continuously. This may result in black print on any portion of the page. a. Make sure the paper brush is properly seated into position. The grounding spring must make good physical contact with the printer base pan. Remove the paper brush and see if the error still occurs. Replace the brush if the lines are not present with the brush removed. b. Make sure the grounding spring on the paper brush is not corroded or bent. Replace it if necessary. c. Make sure the grounding spring is making good contact with the roller shafts of the paper brush. Use conductive grease if necessary to insure good contact.
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d. Replace the paper brush if the above steps do not remedy the problem. e. The Engine Controller Board has been damaged by static and must be replaced. f. The laser has been damaged and the LSU must be replaced. 522. The static brush on the transfer charger has been damaged and is causing static discharges to the laser. a. Check to make sure the brush is not damaged and is in good physical contact with the transfer charger frame. Follow these steps if the entire page has black print or the above steps did not fix the problem on pages with intermittent black areas: 523. The OPC drum charge is intermittent on pages of partial black print, or is not present on pages with all black print. a. Check the contact between the H.V.P.S. and the OPC drum. Make sure there is no corrosion and that the H.V.P.S. contact spring is not compressed. Pull the spring to lengthen it if necessary. Make sure to pull the spring upward, not at an angle. b. The OPC drum is not holding a charge, and the OPC drum unit must be replaced. c. The H.V.P.S. is not supplying the proper OPC drum charge. Adjust the H.V.P.S. drum charge according to the procedure in Chapter 8, Power Supplies. If there is no charge or the proper charge cannot be obtained, replace the H.V.P.S. d. The L.V.P.S. is not supplying the correct voltage to the H.V.P.S. and must be replaced. e. The Engine Controller Board is not turning on the power supplies at the proper time and must be replaced. f. The laser in the LSU is defective and the LSU must be replaced. 524. The H.V.P.S. is supplying intermittent voltages to the OPC drum. This usually results in pages with intermittent black areas on them. a. The H.V.P.S. is beginning to fail and must be replaced. 530. 531. Dirty background in unprinted areas. The developer sleeve is not receiving the correct voltage. a. The contact between the developer sleeve and the contact spring from the H.V.P.S. is faulty. Check for corrosion and a compressed spring. The contact may also be faulty inside the developer unit itself. Replace the developer unit if the problem cannot be corrected. b. The H.V.P.S. is not supplying the correct voltage. Adjust it according to the procedure in Chapter 8, Power Supplies. c. Replace the power supply if the correct voltage cannot be obtained. 532. The OPC drum is not holding a charge. a. The drum has been worn out and the OPC drum unit must be replaced. 533. The H.V.P.S. voltage for the OPC drum is incorrect.
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a. Check the contact between the H.V.P.S. and the OPC drum. Make sure there is no corrosion and that the H.V.P.S. contact spring is not compressed. Pull the spring to lengthen it if necessary. Make sure to pull the spring upward, not at an angle. b. Adjust the drum voltage via the procedure in Chapter 8, Power Supplies. c. Replace the H.V.P.S. if the correct voltage cannot be obtained. 534. The print density is set too high on the H.V.P.S. a. Turn the green density knob on the H.V.P.S. down to a level where the background is no longer dirty. b. If the problem persist after adjusting the green knob, the power supply must be readjusted according to the procedure in Chapter 8, Power Supplies. c. The H.V.P.S. must be replaced if the proper voltage cannot be obtained. 535. The doctor blade gap of the developer unit is too large. If this is the cause, the dirty background will disappear as soon as a new developer unit is installed. a. Replace the developer unit. 540. Black or white concentric rings.
These look like ripples caused in a pond by a stone being thrown into it. 541. The transfer charger static brush is damaged. It is not removing the residual charge from the paper after the toner transfer process. This causes static discharges to occur on the paper before the toner is fused. The static discharges scatter the toner. a. Replace the transfer charger static brush. 550. 551. The printed image is weak, barely visible. The developer unit is low on toner. a. Install a new toner cartridge onto the developer unit. 552. The green density knob on the H.V.P.S. is set too low. a. The power supply is not supplying enough voltage to the developer sleeve. Turn the knob to a higher setting. 553. The transfer charger is not rising into position. a. Make sure the engagement lever is not binding on the transfer charger. Make sure the lever moves freely. b. Make sure the engagement lever roller is properly seated on the engagement cam lever of the fuser. c. The transfer solenoid is not engaging correctly. Check to make sure the signal to release the solenoid is being sent from the L.V.P.S. 1. If the signal is present, replace the transfer solenoid. 2. If there is no signal, replace the L.V.P.S.
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A. If the solenoid still does not function after replacing the L.V.P.S., replace the Engine Controller Board. d. The transfer charger is not moving freely and must be replaced. 554. The charge on the transfer corona is not at the proper voltage. a. Make sure the contact between the H.V.P.S. and the transfer corona is good. 1. Clean toner or paper dust from the transfer corona contact and the H.V.P.S. spring. 2. Clean off any corrosion on the transfer corona contact. 3. If the spring for the H.V.P.S. contact is compressed, lengthen it by pulling the top of it. This helps ensure the electrical contact. Make sure to pull the spring upward, not at an angle. b. Check the charge from the H.V.P.S., and adjust the power supply if the charge is not correct. Follow the adjustment procedure in Chapter 8, Power Supplies. c. If the charge is still not correct after step b, replace the H.V.P.S. 555. The developer sleeve is not receiving the correct voltage. a. The contact between the developer sleeve and the contact spring from the H.V.P.S. is faulty. Check for corrosion and a compressed spring. The contact may also be faulty inside the developer unit itself. Replace developer unit if the problem cannot be corrected. b. The H.V.P.S. is not supplying the correct voltage. Adjust according to the procedure in Chapter 8, Power Supplies. c. Replace the H.V.P.S. if the correct voltage cannot be obtained. 556. The OPC drum is not properly grounded and the charge is not being dissipated by the laser. a. Check the OPC drum grounding spring for proper contact with the OPC drum shaft. Replace the spring if it is severely bent. b. The OPC drum is defective and should be replaced. 560. 561. The print has many unexplained, seemingly random errors. The contact to the charge grid is poor, resulting in an uneven charge on the OPC drum. a. Replace the OPC drum unit. b. Clean and/or lengthen the spring on the H.V.P.S. contact. c. Check and replace the H.V.P.S. if needed. 570. 571. The print has a dirty background accompanied by a ghost image. The contact to the developer sleeve is poor, resulting in an incorrect developer bias. a. Check the contact spring. Lengthen it if needed by pulling upward. b. Replace the developer unit.
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c. Check the developer bias and replace the H.V.P.S. if needed. 580. The print is intermittently dark, then goes light over a period of 1 to three pages. This may be accompanied by 1.5 inch repeating errors. The inner transfer gear is spinning on the main shaft, resulting in the developer sleeve not turning and not being replenished with toner. The developer sleeve will be grayish in color instead of being black. a. Replace the inner transfer gear. 590. The print appears to be smudged as if something has rubbed the toner before it was fused. The inner transfer gear is slipping, causing the developer gear to turn slower. This causes the OPC drum and developer sleeve to no longer be synchronized. The toner thus drags across the surface of the OPC drum. a. Replace the inner transfer gear in the developer gear assembly. 600. 610. Other Image Errors Vertically blurred image. The image appears to be smudged in an area of the page and the smudge runs the entire length of the page. 611. The unfused toner on the paper is being blurred. a. The toner is being smeared by something in the paper path between the transfer charger and the fuser. The obstruction is usually a piece of paper in the entrance to the fuser. b. The paper is skewing as it enters the printer. This causes the paper to buckle. Make sure the paper is being fed correctly into the printer. 612. The transfer charger static brush is damaged and is not touching the paper at some point. a. Replace the static brush. 613. There is a foreign object that is distorting the laser beam. a. Inspect the LSU cover glass for any obstructions or defects. Clean or replace the cover glass as needed. b. There is a foreign object distorting the beam inside the LSU. Replace the LSU. 620. Vertically compressed image.
581.
591.
The image is compressed or smaller than it should be. It runs the entire width of the page. This is most noticeable in lines of text where one or more lines are compressed. 621. The paper is not feeding at the proper speed through the printer. It is occasionally moving too slowly. (If it were always moving too slowly, a paper jam error would occur.)
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a. The paper is not feeding freely into the printer. Make sure there is nothing binding the paper as it enter or exits the printer. b. The electric clutch is slipping and must be replaced. 622. As well as a compressed image, the printer exhibits more noise than during normal operation. a. The drive belt is damaged or missing a tooth. Replace the belt. b. The spring on the belt tensioner is weak or stretched and must be replaced. This results in the drive belt slipping on the fuser pulley. c. The drive belt pulley on the fuser is damaged and must be replaced. d. The stepper motor is not functioning properly. Replace the stepper motor. e. The stepper motor drive circuitry in the L.V.P.S. is faulty. Replace the L.V.P.S. 630. 631. Ghost or mirror image. The density setting on the H.V.P.S. is too high. a. The green density knob on the H.V.P.S. is set too high, resulting in too much toner being deposited on the OPC drum. There is more toner on the drum than can be transferred to the paper, which results in excess toner being left on the drum. The OPC drum cleaning system cannot handle the excess toner, and some of it is left on the drum after the cleaning process. This residual toner is then deposited on the paper during the transfer process, during the next rotation of the drum. 632. The erase LEDs are not discharging the OPC drum sufficiently. a. Inspect the LED assembly, looking for broken or blocked LEDs. Toner is deposited occasionally on one of the LEDs. The LEDs can be checked by opening the printer cover, defeating the cover open switch, and turning on the printer. The LEDs will illuminate during the power-on sequence. b. The LEDs are not being turned on by the Engine Controller Board. Replace the Engine Controller Board. c. The LED wires are damaged in the LSU cable. Replace the cable. d. The connections for LEDs inside the LSU are faulty. Replace the LSU. 633. The OPC drum cleaning voltage from the H.V.P.S. is not correct. It is either too low or not present. a. Make sure the H.V.P.S. contact springs and the OPC drum unit contacts are clean of toner and are corrosion free. If compressed, the springs can be lengthened by pulling. Make sure to pull the spring upward, not at an angle. b. Check the cleaning voltages according to the procedure in Chapter 8, Power Supplies. c. Replace the H.V.P.S. if the correct voltage cannot be obtained. 634. The OPC drum is worn out or has excessive toner buildup. This usually occurs after the drum count has exceeded 30,000 pages. If the count is this high, the drum should be replaced as its life has been exceeded.
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a. There is a visible toner buildup on the OPC drum. Because the drum surface is coated with photosensitive material, it is impractical to clean it. Replace the OPC drum unit. b. The drum no longer holds a charge and is therefore not being cleaned correctly. Replace the OPC drum unit. 635. The fuser roller has excessive toner buildup or is worn out. a. Occasionally, the fuser wiper becomes saturated with toner and does not clean the fuser roller correctly. Toner builds up on the roller and then becomes burned onto it. Replace the roller or fuser. 636. The developer sleeve is not receiving the correct voltage. The ghosting is accompanied by a dirty background in areas that should be white. a. The contact between the developer sleeve and the contact spring from the H.V.P.S. is faulty. Check for corrosion and a compressed spring. The contact may also be faulty inside the developer unit itself. Replace the developer unit if the problem cannot be corrected. b. The H.V.P.S. is not supplying the correct voltage. Adjust it according to the procedure in Chapter 8, Power Supplies. c. Replace the H.V.P.S. if the correct voltage cannot be obtained. 640. 641. Intermittent black patches. The H.V.P.S. is supplying intermittent voltages to the OPC drum. This usually results in pages with intermittent black areas on them during the first 3 pages of a print job. a. The H.V.P.S. is beginning to fail and must be replaced. 642. The paper is dry and has static buildup. a. In areas of very low humidity, the paper dries out and picks up excessive static charge from the voltages in the printer. The paper must be stored at over 30% humidity in order to avoid problems with excessive static buildup. b. The plastic paper guide on the transfer charger can be replaced by one that is conductive. These are available on an as-needed basis only. This is a very rare occurrence. c. The paper is defective and must be replaced. This is also very rare. 650. Black spots on white print or white spots on black print.
These spots occur at random, and cover the entire page. It looks as if the page has a case of the measles. 651. The paper is dry and has static buildup. a. In areas of very low humidity, the paper dries out and picks up excessive static charge from the voltages in the printer. The paper must be stored at over 30% humidity in order to avoid problems with static buildup. b. The plastic paper guide on the transfer charger can be replaced by one that is conductive. These are available on an as-needed basis only. This is a very rare occurrence.
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c. The paper is defective and must be replaced. This is also very rare. 660. 661. Unfused toner. The temperature of the fuser roller is too low. a. The temperature circuitry is not functioning correctly. Replace the fuser. b. The Engine Controller Board is not turning on the lamp; thus, the temperature is too low. Replace the Engine Controller Board. 670. 671. The top half of the first line of a print job is missing. Check the mylar strip above the transfer corona on the transfer corona assembly channel. Make sure it is not extending over the corona wire. a. Trim the strip back so that it is not covering the wire. b. Replace the transfer corona assembly. 672. This can occur if the user is trying to print on the first line. Printing on the first line is not possible. a. Do not print on the first line of a page. 680. 681. There are patchy light or dark regions on the page. The paper is skewing as it enters the printer. This causes the paper to buckle. a. Position the box of paper in front of the printer so paper feeds straight, not at an angle, into the printer.
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Guide to Error Mesages

Error messages indicate errors that the printer has detected during the power-on self-test or during normal operation. This section provides common printer status and error messages, along with the corrective actions required to return the printer to normal operation. The messages are generated by the Data Controller Board (and its software), then displayed on the printers Control Panel LCD. NOTE: Some printer emulations may include additional error and status messages that are not listed in this manual; see your emulation manual for details on those messages.
Operator-correctable Error Messages

A nonfatal error is any error that requires only operator attention to correct. The errors listed in the table that follows are all nonfatal errors. After you clear an error, the printer will perform its engine self-test. NOTE: You do not have to turn off the printer to clear operator-correctable errors. Table 132. Operator-correctable Error Messages Corrective Action (See Also Operators Guide) See page 1329. See page 1329. See page 1330. See page 1330. See page 1331. See page 1331. See page 1331. See page 1331. See page 1331. See page 1331.
Message 01 CLOSE THE COVER 02 LOAD PAPER 03 ADD TONER AND CHK WASTE BOTTLE 04 INSTALL TONER CUP 05 INSTALL OPC DRUM 06 CLEAR JAM AT FUSER INPUT 07 CLEAR JAM AT FUSER EXIT 08 CLEAR JAM NEAR TOF LEVER 09 CHECK TOF LEVER 19 PAPER CTL ERR Reload Paper
Explanation The printer top cover is open. The printer is out of paper. The printer is out of toner or the developer unit is missing. The waste toner container is missing. The OPC Drum Unit is missing. The fuser entry jam sensor has been activated. The fuser exit jam sensor has been activated. A paper jam has occured in the paper path. Top of form sensor malfunction. A paper jam has occured in the paper path.
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Service Call Error Messages

A fatal error is any error that cannot be corrected by operator actions alone. The errors listed in the table that follows are all potentially fatal errors. However, except for one error, you might be able to clear them by resetting the printer engine. That one exception is the error 33 REPLACE EEPRM, which is fatal and cannot be cleared by resetting the printer engine. NOTE: Before performing any corrective actions, reset the printer engine, as described below. If a given error continues to appear on the LCD after you reset the printer engine, then cycle the power to the printer. If the error persists, it means that the printer requires further service.
Resetting the Printer Engine

To reset the printer engine, press the Up and Next keys on the control panel simultaneously. Table 133. Service Call Error Messages
Message 15 FUSER FAIL Call Service
Explanation A rotation error of the pressure roller cam has occurred. There is an unfused image at the fuser. The pressure roller cam did not stop, or is out of position after a stop attempt, or the sensor is defective. The pressure roller cam did not start, or the sensor is defective. The sensor that detects the position of the Speed Control Paper Guide is defective. One of the thermistor leads or associated wires is broken, or the thermistor is open. The thermistor leads or associated wires are shorted together, or the thermistor is shorted, or the printer temperature is extraordinarily high. The tractor encoder signal is faulty.
Corrective Action See page 1336.
16 FUSER FAIL Call Service
See page 1336.
17 FUSER FAIL Call Service 18 FUSER FAIL Call Service 23 THRMISTR FAIL Call Service 24 THRMISTR FAIL Call Service
See page 1336.
See page 1337.
See page 1337.
See page 1338.
25 ENCODER FAIL Call Service
See page 1332.
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Message 26 HEATER FAIL Call Service 27 HEATER FAIL Call Service 28 BEAM DET FAIL Call Service
Explanation The fuser did not warm up within its specified time. During printing, the fuser is not properly maintaining its temperature. A beam detect failure has occurred. This means that the LSU motor is spinning, but it is not generating interrupts. The LSU phase lock circuit is not sending its Ready signal to the Engine Controller Board. LSU phase lock has been lost. The LSU either has failed to acquire phase lock, or has dropped out of phase lock. The LSU phase lock circuit is sending its Ready signal to the Engine Controller Board, but should not be sending it, since the Engine Controller Board has not enabled the LSU motor. The handshaking has failed between the Engine Controller Board and the Data Controller Board. The EEPROM on the Engine Controller Board has exceeded its life of 100,000 writes. The OPC Drum Unit has exceeded its life of 30,000 eleven-inch-long pages (or equivalent). A checksum error occurred while reading the EEPROM on the Engine Controller Board.
Corrective Action See page 1338. See page 1338.
See page 1339.
29 LSU FAIL Call Service
See page 1340.
See page 1340.
See page 1340.
32 MISPRINT ERROR Call Service
See page 1341.
33 REPLACE EEPRM Call Service
See page 1341.
34 REPLACE OPC DRUM Call Service
See page 1341.
35 EC CKSUM FAIL Call Service
See page 1341.
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Detailed Troubleshooting Guide 01 CLOSE THE COVER

1. The printer top cover is open. a. Make sure the top cover is closed, especially the right side. b. The right clamshell latch is broken and is not tripping the interlock switch on the L.V.P.S. If the latch is broken, make sure the drive belt cover is installed properly. When the drive belt cover is not seated correctly, the clamshell latch will catch and break as it goes through the hole in the cover. 2. The top cover interlock switch is defective. a. The interlock switch on the L.V.P.S. is not functioning correctly. The switch must be replaced on the L.V.P.S. b. The L.V.P.S. is not supplying the 12 V to the switch and must be replaced. c. The Engine Controller Board is not interpreting the cover open signal correctly and must be replaced. d. Check the wire harness from the power supply to the Engine Controller Board and replace the harness if necessary. e. The Data Controller Board is defective and must be replaced.
02 LOAD PAPER
1. There is no paper on the input side of the printer. a. Make sure that there is paper in the printer. b. Make sure that the paper has been fed between the upper and lower paper rollers. The paper must depress the Paper Empty sensor lever. 2. The paper empty sensor is defective. a. Make sure that the sensor lever is not broken or bent; replace it if needed. b. Check the paper empty sensor board for toner or paper dust buildup and clean it if needed. c. The paper empty optical sensor is defective. Replace the paper empty sensor board. d. The Engine Controller Board is faulty and must be replaced. e. The cable for the paper sensor board is faulty and must be replaced. f. The L.V.P.S. is faulty and must be replaced. NOTE: A faulty L.V.P.S. would be unlikely, as there would be numerous other problems with the printer. The paper sensor board uses 5 V, as well as the Engine Controller Board. If the 5 V were not present, the Engine Controller Board and the printer could not function.
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03 ADD TONER AND CHK WASTE BOTTLE

CAUTION: Whenever adding toner, always check the level in the waste toner container, and replace the waste toner container if necessary. (The printer has no sensor for waste toner container full.)
1. Check the level in the waste toner container. If the container is full, replace it. 2. Verify that the developer unit is installed. If it is, reseat it. If the developer unit is missing, install it. 3. The developer unit is low on toner. a. Make sure the toner is evenly dispensed in the developer. If the toner is not covering the toner sensor, the developer will send a toner low error signal to the Engine Controller Board. b. Add toner to the developer unit. 4. The toner sensor in the developer unit is not functioning properly. a. The toner sensor is faulty and the developer unit will need to be replaced. The toner sensor may be replaced on the developer unit. b. The toner sensor is not receiving 5 V. Check the paper-empty sensor board to make sure the voltage is passing through it. Replace the board if necessary. c. The L.V.P.S. is faulty and not supplying 5 V. This is very unlikely as there would be numerous other problems with the printer. The 5 V is used throughout the printer. 5. The Engine Controller Board is not interpreting the toner low signal correctly. a. The Engine Controller Board is faulty and must be replaced. b. The paper empty sensor board is not transmitting the toner low signal and must be replaced. c. The paper empty wire harness is faulty and must be replaced. d. The Data Controller Board is malfunctioning and must be replaced.
04 INSTALL TONER CUP

1. The waste toner container is missing. a. Install a waste toner container. 2. The waste toner sensor is faulty. a. Clean the sensor of any toner, paper dust, paper fragments, or other foreign material. b. Make sure the sensor lever is not damaged or broken and replace it if needed. c. The toner sensor is faulty and the entire sensor board must be replaced. d. The cable for the paper empty sensor board is faulty and must be replaced.
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05 INSTALL OPC DRUM

1. The OPC drum unit is missing. a. Install an OPC drum unit in the printer. 2. The OPC drum unit is not seated correctly, and thus is not activating the Drum-In Sensor. a. Remove and reseat the OPC drum unit. 3. The Drum-In Sensor is faulty. a. Replace the sensor.
06 CLEAR JAM AT FUSER INPUT

1. The fuser entry jam sensor has been activated. a. Clear the paper jam in the paper entry area of the fuser. b. See the General Paper Jam Troubleshooting section that follows.
07 CLEAR JAM AT FUSER EXIT

1. The fuser exit jam sensor has been activated. a. Clear the paper jam in the paper exit area of the fuser. b. See the General Paper Jam Troubleshooting section that follows.
08 CLEAR JAM NEAR TOF LEVER

1. A paper jam has occured in the paper path. a. Clear the paper jam along the paper path of the printer, probably in the area of the TOF lever (between the tractors and the fuser). b. See the General Paper Jam Troubleshooting section that follows.
09 CHECK TOF LEVER

1. The TOF sensor is off when the paper set is ok. a. Check the plastic TOF lever (flag assembly). b. Check the microswitch controlled by the TOF lever. c. See the General Paper Jam Troubleshooting section that follows.
19 PAPER CTL ERRReload Paper

1. A paper jam has occured in the paper path, or the Speed Control Paper Guide is not moving properly between its upper and lower limits, or the Speed Control Paper Guide Sensor is defective. a. Clear the paper jam along the paper path of the printer, probably in the area of the Speed Control Paper Guide (between the tractors and the fuser). b. Check the Speed Control Paper Guide.
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c. Check the Speed Control Paper Guide Sensor. d. See the General Paper Jam Troubleshooting section that follows.
25 ENCODER FAILCall Service

1. The tractor encoder signal is faulty. a. Clean any toner or paper dust out of the encoder sensor. b. Inspect the tractor encoder wheel for damage. Replace it if necessary. c. The encoder sensor is faulty. Replace the tractor encoder board or the entire tractor unit. d. The fuser drive clutch is slipping; replace it. e. Replace the Engine Controller Board. f. Replace the encoder cable. g. See the General Paper Jam Troubleshooting section that follows.
General Paper Jam Troubleshooting

Paper jam errors can come from a number of different sources. The way in which the paper jam error occurs is a very useful tool in determining what component is causing the error. For instance, how the printer reacts during the top-of-form (TOF) reset will help indicate what component is at fault. If a paper jam error occurs immediately, before the paper moves, the paper jam sensor in the fuser heat shield is most likely at fault. If the jam occurs after the paper moves about 1/2 inch, the tractor encoder may be at fault. 1. Visible paper jam. This section deals with errors where there is a real paper jamthat is, where error messages are being displayed and a paper jam is visible. If error messages are being displayed but there is no visible paper jam, see the section on page 1334. When a jam occurs, the paper will start buckling or bunching until it strikes the paper jam sensor in the fuser heat shield. The paper usually becomes compressed like an accordion. a. The paper jams as it exits the fuser and printer. 1) Carefully clear the jam so that none of the fuser components become damaged. The separator springs in the fuser rear cover can be bent or damaged easily if the jammed paper is not carefully removed. 2) If the jam reoccurs, check the separator springs for damage and replace parts as needed. 3) Check the other components of the fuser rear cover for damage and replace parts as needed. 4) The paper is adhering to one of the rollers, causing the jam. Replace the entire fuser unit. 5) Make sure the exiting paper has room to stack as it exits the printer. b. The paper jams as it enters the fuser. 1) Carefully clear the jam, making sure that the plastic top-of-form (TOF) lever (flag assembly) does not become damaged. a) Check the TOF lever to make sure it moves freely. If it is not moving freely, check to see if it is binding on the edge of the hole in the fuser
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paper guide. If it is not binding on the hole, replace the lever and its stand. b) If the lever is still binding or striking the edges of the hole in the fuser paper guide, replace the guide. 2) Reset the paper into the tractor assembly. Make sure the leading edge of the paper is not torn or wrinkled, since this will cause jams as the paper enters the fuser. 3) Make sure the paper is stretched tightly between the tractors so that it is not bowed. Bowed paper will tend to catch as it enters the fuser. 4) Check the fuser paper guide to make sure it is not bent or damaged and replace it if needed. c. The paper is jammed, bowed, or buckled between the OPC drum unit and the fuser. This causes the paper to lift off of the TOF lever, which causes a paper jam error. NOTE: During the registering (setting) of top of form, the tractor pulls the paper through the printer until it reaches the fuser. Once the paper has entered the fuser, the fuser is the drive mechanism for the paper. It pulls the paper through the printer at a slightly faster rate than the tractor does, thus keeping the paper tight between the tractor and the fuser. If the rollers in the fuser do not turn, or the rollers are worn so that their diameter is smaller, the tractor will pull the paper through the printer faster than does the fuser. This causes the paper to bow upward and lift off of the TOF lever, or strike the paper jam sensor. When the printer is open, this might not be visible, because when an error occurs, the fuser opens and the paper tends to lay flat again. To check for this bowing phenomenon, turn off the printer while it is still printing and a number of pages have been printed. Do this while the printer is actually printing. The fuser will stay closed and any bow of the paper will be visible when you open the printer. Verify that the rollers are turning by opening the top cover of the printer, defeating the cover open switch, resetting the paper in the tractor, and resetting TOF. Turn on the printer and watch the fuser as the top of form is being set. The fuser should be closed and the rollers turning as the paper enters the fuser. If the rollers are not turning, repeat this step and see if the drive belt, fuser drive clutch and gear, and electric clutch are turning. 1) The fuser is not closing. a) Replace the Engine Controller Board. Step 1) is very unlikely. In order for step 1) to occur at this point, the printer would have to fail its power-on self-test. The fuser cam motor is cycled during the power-on self-test. If the fuser does not close and then open, a FUSER FAIL error will occur. If this error does not occur, the Engine Controller Board is faulty. 2) The fuser roller is not turning. a) The drive belt is turning. 1] The drive belt is turning the drive pulley assembly but the fuser roller is not turning. a] The fuser drive gear in the pulley assembly is not turning, but the belt pulley is turning. This indicates that the drive pulley clutch inside the assembly is defective, and the pulley assembly must be replaced.
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b] The fuser drive gear in the pulley assembly is turning, but the fuser drive gear on the fuser is not turning. The fuser drive gear must be replaced. c] The gear on the fuser roller is turning, but the roller is not turning. This indicates that the engagement teeth on the gear are broken, and the fuser roller gear must be replaced. 2] The drive belt is not turning the drive pulley. a] The drive belt is slipping on the fuser pulley. If this is happening, there should be excessive noise coming from the pulley and belt as the slipping occurs. 1} The belt tensioner spring is weak and must be replaced. 2} The pulley teeth are worn and the pulley assembly must be replaced. 3} The drive belt teeth are worn and the belt must be replaced. b) The drive belt is not turning, but the main gear assembly is turning. 1] The electric clutch assembly is turning, but the drive belt is not. a] The belt tensioner spring is loose and the belt is not being driven. Replace the belt tensioner spring. b] The teeth on the electric clutch pulley are worn and the electric clutch must be replaced. c] The drive belt is worn and must be replaced. 3) The pressure roller is not turning. a) A foreign object is rubbing on the pressure roller or touching it. The foreign object must be removed and the roller inspected for damage. If the foreign object cannot be removed or the roller is damaged, the fuser unit must be replaced. b) The bearings on the pressure roller are worn. The entire fuser unit must be replaced. 4) The rollers in the fuser are turning. The paper jam error occurs after the printer has been operating for a prolonged period of time. There is an upward bow present in the paper when the printer is stopped during the print process. a) The drive belt is slipping. 1] The belt tensioner spring is loose and the belt is slipping. Replace the belt tensioner spring. 2] The teeth on the clutch pulley are worn and the electric clutch must be replaced. 3] The drive belt is worn and must be replaced. b) The fuser rollers are worn to a much smaller diameter than when they were new. The fuser can no longer pull the paper through the printer at a rate that is faster than the tractor. The entire fuser must be replaced. 2. Paper jam errors, but no jam visible. This section deals with paper jam errors where error messages are being displayed but there is no visible paper jam. If a paper jam is visible, see the section on page 1332. a. The following paper jam errors occur after the printer has passed its power-on self-test and is ready for a print job. This will be evident by the READY light on the LCD Control Panel being illuminated.
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The paper jam error occurs because the paper is not being fed at the proper speed. When the paper is moving at the correct speed, the tractor encoder generates pulses at a fixed rate. As the paper feed rate slows, the time interval between pulses increases. When the Engine Controller Board detects that the time interval between pulses is too long, it signals a paper jam error. 1) The paper jam error occurs after the printer has been operating for a prolonged period of time and the printed image seems to be compressed. a) The paper is binding or is skewing as it enters the printer. Make sure that the paper source is aligned with the printer, and that the paper is not dragging over any foreign objects before it enters the printer. b) The stepper motor is not driving the gear train at the correct speed. 1] A drive gear from the stepper motor to the rest of the gear train is slipping, and the main gear assembly must be replaced. 2] The stepper motor is faulty and must be replaced. 3] The drive circuitry for the motor is faulty. The L.V.P.S. must be replaced because it contains this circuitry. 2) The paper jam error occurs after the printer has been operating for a prolonged period of time. The bowing problem described in step 1., c., 4) is not evident. a) The electric clutch is slipping and must be replaced. b) The drive belt is slipping. 1] The belt tensioner spring is loose and the belt is slipping. Replace the belt tensioner spring. 2] The teeth on the clutch pulley are worn and the electric clutch must be replaced. 3] The drive belt is worn and must be replaced. c) The stepper motor is not driving the gear train at the correct speed. 1] A drive gear from the stepper motor to the rest of the gear train is slipping, and the main gear assembly must be replaced. 2] The stepper motor is faulty and must be replaced. 3] The drive circuitry for the motor is faulty. The L.V.P.S. must be replaced because it contains this circuitry. d) The Engine Controller Board is faulty and must be replaced. b. A paper jam error occurs immediately after the printer is powered on. 1) The paper jam sensor is giving an error condition. a) Make sure the jam sensor lever is not stuck. b) The jam sensor cable is not connected to the LSU. c) The jam sensor switch is faulty and must be replaced. d) The jam sensor wires inside the LSU cable are damaged. The LSU cable must be replaced. e) The Engine Controller Board is faulty and must be replaced. f) The connector in the LSU for the jam sensor switch is faulty. The LSU must be replaced. c. The paper jam error occurs after the printer completes the warmup cycle during the power-on self-test. The printer tries to register TOF, but the paper never moves. 1) The electric clutch assembly is not engaging. a) The electric clutch is faulty and must be replaced. b) The electric clutch is not being activated. 1] The Engine Controller Board is faulty and must be replaced.
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2] The L.V.P.S. is not supplying the 24 V to the clutch, and the L.V.P.S. must be replaced. This is unlikely, as several other components use 24 V, and other errors would be occurring during the power-on self-test. d. The paper jam error occurs after the paper moves about 1/2 inch during TOF registration. 1) The tractor encoder signal is faulty. a) Clean any toner or paper dust out of the encoder sensor. b) Inspect the tractor encoder wheel for damage. Replace it if necessary. c) The encoder sensor is faulty. Replace the tractor encoder board or the entire tractor unit. d) The fuser drive clutch is slipping; replace it. e) The Engine Controller Board is faulty; replace it. f) The encoder cable is faulty; replace it.
15 FUSER FAILCall Service

1. A rotation error of the pressure roller cam has occurred. There is an unfused image at the fuser. a. Check the operation of the pressure roller cam. Replace it if necessary. b. Inspect the pressure roller clutch and associated wiring. Repair any wiring problems found. c. Replace the Fuser Sensor Board. d. Replace the Stepper Motors Controller Board. e. Replace the Engine Controller Board. f. See the General Fuser Cam Troubleshooting section that follows.

1. The pressure roller cam did not stop, or is out of position after a stop attempt, or the sensor is defective. a. Check the operation of the pressure roller cam. Replace it if necessary. b. Inspect the pressure roller clutch and associated wiring. Repair any wiring problems found. c. Replace the Fuser Sensor Board. d. Replace the Stepper Motors Controller Board. e. Replace the Engine Controller Board. f. See the General Fuser Cam Troubleshooting section that follows.

1. The pressure roller cam did not start, or the sensor is defective. a. Check the operation of the pressure roller cam. Replace it if necessary. b. Inspect the pressure roller clutch and associated wiring. Repair any wiring problems found.
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c. Replace the Fuser Sensor Board. d. Replace the Stepper Motors Controller Board. e. Replace the Engine Controller Board. f. See the General Fuser Cam Troubleshooting section that follows.
General Fuser Cam Troubleshooting

With the top cover open, defeat the cover open switch and turn on the printer. Watch the fuser to see if it closes, then opens, during the power-on sequence. If the fuser does not cycle, check the resistance of the fuser cam motor. Disconnect the motor cable and measure the motor resistance. If the motor is open, it is defective and must be replaced. Also, check the 24 V from the L.V.P.S. 1.The fuser cycles during power-up, but a FUSER CAM error still occurs. a. The fuser cam motor signal is faulty. 1) Check the fuser cam sensor wheel for damage and replace it if necessary. 2) The fuser sensor board is faulty and must be replaced. 3) The cable from the fuser sensor board is faulty and must be replaced. 4) The Engine Controller Board is faulty and must be replaced. 2. The fuser does not cycle during power-up. a. There is 24 V being supplied from the L.V.P.S. to the fuser cam motor. 1) The fuser cam motor is faulty and must be replaced. 2) The cable for the motor is faulty and must be replaced. 3) The fuser is binding and the motor cannot close the fuser. The fuser must be replaced. CAUTION: If the fuser is binding and, after installing a new motor, you hear some severe gear grinding or motor binding noise while the motor tries to close the fuser, the binding fuser will cause the motor to burn out.
b. The L.V.P.S. is not supplying 24 V to the fuser cam motor. Check the OPC drum during the power-up sequence to see if it turns. The 24 V is also supplied to the stepper motor, causing the OPC drum to do a cleaning cycle during the power-up sequence. If the OPC drum and stepper motor are turning, the power supply is probably good. 1) If the OPC drum is turning, replace the Engine Controller Board. 2) If the OPC drum does not turn, replace the L.V.P.S. 3) Replace the cabling between the L.V.P.S. and the fuser.

1. The sensor that detects the position of the Speed Control Paper Guide is defective. a. Replace the sensor for the Speed Control Paper Guide. b. Replace the Speed Control Paper Guide.
23 THRMISTR FAILCall Service

1. The thermistor in the fuser is open, or one of its leads or associated wires is broken. a. Inspect the thermistor leads and associated wiring. Repair any wiring problems found.
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b. Check the thermistor. Replace it if necessary. c. See the General Fuser Heater Troubleshooting section that follows.
24 THRMISTR FAILCall Service

1. The thermistor in the fuser is shorted, or its leads or associated wires are shorted together, or the printer temperature is extraordinarily high. a. Inspect the thermistor leads and associated wiring. Repair any wiring problems found. b. Inspect the heater lamp leads and associated wiring. Repair any wiring problems found. c. Check the thermistor. Replace it if necessary. d. Check the heater lamp in the fuser. Replace it if necessary. e. See the General Fuser Heater Troubleshooting section that follows.
26 HEATER FAILCall Service

1. The fuser did not warm up within its specified time. a. Check for a tripped or defective circuit breaker. Replace the breaker if necessary. b. Inspect the thermistor leads and associated wiring. Repair any wiring problems found. c. Inspect the heater lamp leads and associated wiring. Repair any wiring problems found. d. Check the thermistor. Replace it if necessary. e. Check the heater lamp in the fuser. Replace it if necessary. f. See the General Fuser Heater Troubleshooting section that follows.
27 HEATER FAILCall Service

1. During printing, the fuser is not properly maintaining its temperature. a. Inspect the heater lamp leads and associated wiring. Look for a faulty or loose connection that could cause an intermittent open circuit in the heater circuit. Repair any wiring problems found. b. Inspect the thermistor leads and associated wiring. Look for a faulty or loose connection that could cause an intermittent short circuit in the thermistor circuit. Repair any wiring problems found. c. Check the thermistor. Replace it if necessary. d. Check the heater lamp in the fuser. Replace it if necessary. e. See the General Fuser Heater Troubleshooting section that follows.
General Fuser Heater Troubleshooting

1. The fuser is not reaching the correct temperature. This can indicate either overheating or underheating.
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Follow the procedures for fuser testing in Chapter 7, Fuser Subsystem. These procedures are very helpful in learning how the fuser works and in determining what component is at fault. Look through the cooling holes in the rear of the top cover of the printer to see if the lamp is lit during the warmup cycle. This will help to isolate the problem. If the fuser is underheating and does not reach the correct temperature in a fixed amount of time, an error will occur. If the fuser overheats, it will cause the thermal breaker to trip, and the lamp will not light at all. a. Follow these steps if the lamp is lit during the warmup cycle: 1) Make sure the thermistor does not have excessive toner buildup on it, which will cause overheating. Clean or replace the thermistor. NOTE: In a normal overheating condition, the thermal breaker will trip when the fuser temperature reaches the tripping point of the breaker. When there is toner buildup on the thermistor, the temperature will exceed the breakers trip point, and the breaker will trip. This stops the flow of current to the lamp, and the fuser will no longer heat. 2) The thermistor itself is not functioning correctly, and must be replaced. It may be intermittent, or it may be sending erroneous information. 3) The Digital-to-Analog converter for the thermistor is faulty. The Engine Controller Board must be replaced. 4) The reference resistor on the fuser sensor board is faulty. This resistor sets the reference voltage for the desired fusing temperature. The fuser sensor board must be replaced. 5) The Data Controller Board is requesting status from the Engine Controller Board too often. The Data Controller Board is requesting status information from the Engine Controller Board at a rate faster than once every 10 ms (may vary depending on the controller). The Engine Controller Board does not have time to perform the Digital-to-Analog and Analog-to-Digital conversions for the fuser temperature circuitry. The Data Controller Board must be replaced. b. Follow these steps if the lamp is not lighting: 1) The thermal breaker has tripped due to an overheat condition. Remove the breaker, measure its resistance, and replace it if it is open (infinite resistance). 2) The lamp is open or broken. Check its resistance to see if it is open, and replace the lamp if its resistance is more than 2 ohms. 3) Fuse F2 is blown in the L.V.P.S. This prevents 110 V (or 220 V) from being supplied to the lamp. 4) The thermistor is faulty and must be replaced. Disconnect its cable from the fuser sensor board and measure its resistance. Make sure the thermistor is not open. 5) The Fuser Sensor Board is faulty and must be replaced. 6) The Digital-to-Analog converter is faulty and the Engine Controller Board must be replaced.
28 BEAM DET FAILCall Service

1. A beam detect failure has occurred. This means that the LSU motor is spinning, but it is not generating interrupts. a. Check the wiring to the LSU. Repair any wiring problems found. b. Replace the L.V.P.S. c. Replace the LSU.
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d. Replace the Engine Controller Board. e. See the General LSU Troubleshooting section that follows.
29 LSU FAILCall Service

1. The LSU phase lock circuit is not sending its Ready signal to the Engine Controller Board. a. Check the wiring to the LSU. Repair any wiring problems found. b. Replace the L.V.P.S. c. Replace the LSU. d. Replace the Engine Controller Board. e. See the General LSU Troubleshooting section that follows.

1. LSU phase lock has been lost. The LSU either has failed to acquire phase lock, or has dropped out of phase lock. a. Check the wiring to the LSU. Repair any wiring problems found. b. Replace the L.V.P.S. c. Replace the LSU. d. Replace the Engine Controller Board. e. See the General LSU Troubleshooting section that follows.

1. The LSU phase lock circuit is sending its Ready signal to the Engine Controller Board, but should not be sending it, since the Engine Controller Board has not enabled the LSU motor. a. Check the wiring to the LSU. Repair any wiring problems found. b. Replace the L.V.P.S. c. Replace the LSU. d. Replace the Engine Controller Board. e. See the General LSU Troubleshooting section that follows.
General LSU Troubleshooting

1. This is an error that has been detected in the LSU. Many things can cause this error. A beam detect problem, a polygon motor problem, or abnormal power to the laser can all cause this error. a. The LSU cable is faulty and must be replaced. b. The L.V.P.S. is not supplying the correct voltages to the LSU. The L.V.P.S. must be replaced. c. One of the above errors has occurred in the LSU and the entire LSU must be replaced. d. The Engine Controller Board is faulty and must be replaced.
1340
32 MISPRINT ERRORCall Service

1. This usually indicates a handshaking or communication error between the Engine Controller Board and the Data Controller Board during normal operation. One board is not responding to the others command or request for status. a. Cycle power to the printer. If the error returns, continue with the following steps. b. Verify that the Engine Controller Board and the Data Controller Board are properly seated on the Backplane Board. c. The Engine Controller Board is not responding to the Data Controller Board. Replace the Engine Controller Board. d. The Data Controller Board is not responding to VSREQ soon enough. Replace the Data Controller Board.
33 REPLACE EEPRMCall Service

1. The life count of the EEPROM on the Engine Controller Board has exceeded 100,000 writes. The EEPROM stores all of the page counts for the components of the printer. Data is written to the EEPROM every time the printer is powered down. a. Record all page counts, then replace the NVRAM chip on the Engine Controller Board. b. The Engine Controller Board is faulty and must be replaced. c. The Data Controller Board is faulty and must be replaced.
34 REPLACE OPC DRUMCall Service

1. The page count of the OPC Drum Unit has exceeded 30,000 pages (normalized to an 11 inch page length). CAUTION: If you ignore this error message, the printer will continue to print, but the print quality will become unacceptable.
a. Replace the OPC Drum Unit. b. The NVRAM chip on the Engine Controller Board is not recording page counts correctly. Replace the NVRAM chip on the Engine Controller Board. c. The Engine Controller Board is faulty and must be replaced.
35 EC CKSUM FAILCall Service

1. A checksum error occurred while reading the EEPROM on the Engine Controller Board. a. Replace the NVRAM chip on the Engine Controller Board. b. The Engine Controller Board is faulty and must be replaced.
1341
TOF REGISTRATION ERRORS

1. The positioning of the tractor encoder is incorrect. a. Check the mounting bracket for the encoder board on the tractor frame. Make sure the bracket is not loose and that the encoder board is also securely fastened to the bracket. b. The position of the first line of print can be adjusted by raising or lowering the encoder mounting bracket on the tractor frame. 2. The printer thinks that TOF is set, but it is not. This will be evident by the ready light being illuminated and the paper not being in the fuser. The printer starts a print job and feeds paper into the fuser. The first line of print will be about midway down the page. a. The plastic TOF lever (flag assembly) is stuck in the depressed position. Clear the lever and make sure there are no damaged parts. b. The TOF optical sensor is faulty and the entire fuser sensor board must be replaced. c. The cable for the TOF sensor board is faulty and must be replaced. d. The Engine Controller Board is faulty and must be replaced.
1342
Appendix A Printer Specifications
Mechanical Printing Method: Photosensitive Material: Imaging Device: Toner: Fuser: Dimensions: Electrophotographic, using diode laser (black writing) Organic Photoconductor (OPC) drum Laser diode 1-1/2 component toner / developer system Heat and pressure roller, with electronic temperature selection and control H = 9.8 inch (25 cm) W = 18.2 inch (46 cm) D = 19.3 inch (49 cm) (with Entry Paper Guide and Exit Paper Guide removed) Weight (Printer Only): Case: Electrical Operation: 90 to 132 VAC @ 47 to 63 Hz (single phase) 198 to 264 VAC @ 47 to 63 Hz (single phase) < 1500 Watts (Peak while fusing) < 1000 Watts (Average while fusing) Standby Mode: Energy Saving Mode: Recommended Cooling: < 300 Watts (average for 80 F ambient) < 45 Watts 4000 BTU/hr @ 100% printing 58 lbs. (26.3 kg), including printer; excluding packaging and consumables Impact-resistant plastic
A1
Environmental Operation: Tilt: Temperature: Relative Humidity: Altitude: Shipping / Storage: Shipping Temperature: Storage Temperature: Relative Humidity: Noise: Standby: Operating: Regulatory Approvals Electrical: UL1950 CSA C22.2 No. 220ml986:DIN IEC 950 / EN60950 Electromagnetic: Laser: FCC Class A, Part 15, Subpart J TUV (VDE) 0871, Class B FDA / CDRH 21CFR TUV EN60825 SP (Sweden) < 47 dBA < 53 dBA 30 to +60 C (22 to +140 F) for 200 hours Same as Shipping 10 to 95% RH, noncondensing 5 maximum 10 to 32.5 C (50 to 90.5 F) 20 to 85% RH, noncondensing 7500 feet (2286 m) maximum
Document Handling Method: System: Paper: Type: Width: Length: Weight: 0.5 inch pitch tractor feed pin holes Min. 4.0 inches, edge-to-edge; 3.5 inches, pin-to-pin Max. 10 inches, edge-to-edge; 9.5 inches, pin-to-pin 3.0 to 33 inches in 1/8 or 1/6 inch increments 18 to 42 lb. Bond 60 lb. Tag Stock / 99 lb. Card Stock 50 lb. Book Carrier / 40 to 60 lb. Label Stock Acrylic Adhesive Label Stock Max. width 8.25 inch Min. length 3.0 inch Max. length 33 inch Portrait or landscape Straight-through tractor feed 6-pin pull tractors, auto-centering
Printable Area:
Image Orientation:
A2
Performance Resolution: Line Width: Print Density: Speed: Reliability: MTBF: MTTR: Duty Cycle: Time to First Print: 300,000 pages 30 minutes maximum 50,000 pages per month < 18 seconds (from operating temperature) < 30 seconds (from standby temperature) < 3 minutes (from ambient temperature) 300 x 300 dots per inch 6.8898 0.98 mils (175 25 mm) 1.3 optical density nominal 0.3 Up to 24 pages per minute (11 inch length)
Controller Data Controller Board, includes: Motorola 68EC03040 32-bit, 40 MHz microprocessor 8 MB DRAM, expandable to 40 MB, in increments of 4 MB or 16 MB 64 KB EPROM (boot ROM) 32 KB NVRAM Interface to Engine Controller Board Interface to Control Panel RS232, RS422, and Centronics interfaces Floppy disk controller Interfaces: Standard: Optional: Centronics parallel interface, RS232 / RS422 serial interface Coax / Twinax interface, Ethernet LAN interface, Dataproducts parallel interface Printronix LP+ impact printer emulation HP PCL5 emulation, IGP / VGL emulation, IGP / PGL emulation 1 floppy disk drive; 3.5 inch, double-sided high density (DSHD), 1.44 MB, DOS format (second floppy disk drive optional)
Emulations: Standard: Optional:
Storage Media
Main Parts Lifetime Machine: Toner: Felt wiper: Waste toner container: 3,000,000 pages or 5 years 8,000 pages 8,000 pages 8,000 pages
A3
OPC drum unit: Developer unit: Ozone filter: Fuser unit:
30,000 pages 100,000 pages 100,000 pages 300,000 pages
A4
Appendix B Wire Data
B1
MAIN STEPPER MOTOR (M1) +24VB 202390 +24VB A B /A /B
OZONE FAN 202171 E504 CN7
CN3

CN8
1 2 3
TMRPWR TMRSG 202200 S802
CN4 1 /OPC /NEWOPC TMRSG TMRPWR 5 /OZNFAN /PRCL PHA1 PHB1 /PHA1 10 /PHB1 1 6 +24VB A B /A /B +24VB COPEN
CN2 PDWN1 PHA2 PHB2 /PHA2 15 /PHB2 PDWN2 PHA3 PHB3 /PHA3 20 /PHB3 PDWN3 +5VL +24VB 24
CN6 1 2 1 +24VB
CN5 6 8 +24VB A B /A /B BGND
CN1 BGND BGND +24 +24 +24 GND +5 1
202298 S208
PRFAN1 PRFAN2
202241 S212
202238 D112
J2 202234 D162 J3
PR CLUTCH
FUSER STEPPER MOTOR (M3)
1 202296 S210
202392
JAM SENSOR
J4
J1
FUSER BASE UNIT

EXIT JAM SENSOR 202234 D162 10 J5
202153 G112 PTOP SENSOR
202299 S206
TRACTOR STEPPER MOTOR (M2)
J2 J1 202158 S102 ENCODER BOARD 202291 S202
TRACTOR UNIT
B2
FUSER UNIT
*
6 1
AC POWER INLET CNS1 CN3 220 110 202576 S801 3 2 CN4 1 + 1 2 COOLING FAN
TMRPWR TMRSG
LOW VOLTAGE POWER SUPPLY
+5 1 DGND +24 +24 +24 5 BGND BGND BGND +24 BGND 10 +12 12 AGND AGND PWROFF /HEAT 16
202292 S211
+5 +5 +5 +5
202298 S208 AGND AGND PWROFF /HEAT
(TO ENGINE CONTROLLER BOARD) +5 /PRPOS 1 /PRINIT /SCPUP /SCPDN PJAM EJAM DGND +24 /PRFAN 10 J5 1 2 3 4 5 6 7 8 J1
(TO DATA CONTROLLER BOARD) J2
+24 BGND +12 12
10
J8
J7 1 J15 4 (NOT USED)
BACKPLANE BOARD
J3 (TO LCD CONTROL PANEL) RSVD Vss Vdd RS R/W E DB0 DB1 9 10 11 12 13 14 15 16 DB2 DB3 DB4 DB5 DB6 DB7 /SWRST /SWONL J3 24 1 1 5 17 /SWFF 18 /SWMENU 19 /SWSTOR 20 /SWUP 21 /SWDWN 22 /LRDY 23 /LONLN 24 /LDATA J4 +12 /QLED +24 BGND /PMON /PMRDY +5 DGND /BD +5 DGND /LDON /LVIDEO LVR 10 14
DGND DGND DGND DGND
+5 +5 +5 +5
DGND DGND DGND DGND 202375 S207
240V to Pin 3
* 120V to Pin 2
CN2
CN1
1 J14 4 (NOT USED)
201153 S203 J6
LCD CONTROL PANEL
202294 S204 TO LSU
1 J10

DEVELOPER BIAS
6 24 1 J13 J9 5 J11 4 1
1 J1 4
TONER SENSOR BOARD
CN1 CN2
TONER SENSOR
DEVELOPER
B3
B4
Appendix C Continuous Form Stacker
Introduction The continuous-form active stacker provides reliable stacking of continuous-form media, whether paper or label stock, at speeds of up to 24 forms (11 inch) per minute. Both models feature a built-in printer support table and an integrated power cable which connects directly to your printer. The stacker is available in a continuous model that is, it runs continuously whether the printer is currently printing or not and an automatic control model (a model that can be turned ON and OFF by a printer equipped with a control port and cable). Safety Precautions The continuous-form stacker requires caution in the following areas: S Since the unit is powered by 115 or 230 volts, standard precautions should be utilized: Use the proper cord for the voltage available, and do not use any cord that is frayed or damaged. S Confirm that the unit is unplugged before service. S If the fuse blows, be sure to replace it with an exact duplicate (Printronix part #704968018). S Do not operate the stacker in a wet environment. S Operate the stacker on a flat surface (5 degrees). S Be careful not to pinch your fingers in the front or back pulleys. S Be sure the locking casters are locked when operating the stacker, and that they are unlocked when moving the unit.
C1
Parts Identification
This section identifies the major subassemblies and components which are available for replacement from Printronix.
C2
(See page C5)
(See page C7)
(See page C15)
(See page C11)
(See page C13)
Figure C1. Continuous Form Stacker
C3
Callout
A 10 15
Name
Guide Assembly, Upper Idler Weight, Stacker Cotter Key, Hairpin
Printronix Part No.

704968008 704968025 704968022
Quantity
1 1 2
C4
10 1
15 2
Figure C2.
C5
Callout
20 25 30
Name
Spring, Coupler, Stacker Cover, Motor, Stacker Motor Assy, 115V, Upper Roller Motor Assy, 230V, Upper Roller
Printronix Part No.

202894001 704968024 704968010 704968027
Quantity
1 1 1 1
C6
(See page C9 )
20 1
(See page C9)
30 Ref 25 1 30 Ref 30 1
Figure C3.
C7
Callout
35 40 45 50 55
Name
Drive, Roll Shaft, Drive Fuse Drawer, 115V Fuse, ABC, 15.0A Power Entry Module
Printronix Part No.

704968023 704968020 704968019 704968018 704968004
Quantity
2 1 1 1 1
C8
35 2
40 1
55 1 50 1
45 1
Figure C4.
C9
Callout
60
Name
Wing, Side Guide
Printronix Part No.

704968017
Quantity
2
C10
60 2
Figure C5.
C11
Callout
65 70 75 80 85 90 95
Name
Motor Assy, 115V, Belt Motor Assy, 230V, Belt Idler, Pulley Assy Belt, Paddle Stacker Paddle Drive Pivot Bracket, Paddle Drive Clamp, Paddle Drive Bracket, L, Stacker
Printronix Part No.

704968028 704968029 704968009 704968016 704968012 704968011 704968015 704968014
Quantity
1 1 1 1 1 1 1 1
C12
65 Ref
65 1 65 Ref
80 1 85 1 90 1
95 1
75 1 70 1
Figure C6.
C13
Callout
100 105 110 115
Name
Power Switch, Rocker Caster, Locking Caster (21/16) Cable, Paper Tray Spring Assy, Stacker
Printronix Part No.

704968005 704968002 704968003 704968007 704968006
Quantity
1 2 2 1 1
C14
115 1
100 1 110 1
ROTATED 180
105 2
Figure C7.
C15
Disassembly/Reassembly
This section provides instruction on the disassembly and reassembly of various stacker assemblies. Required Tools S S S S S S S S S S S S S Small Phillips Screwdriver Medium Phillips Screwdriver Needlenose Pliers 1.5mm Allen Wrench 2.5mm or 5/32 Hex-head Allen Wrench 5mm Allen Wrench 9/16 Open-end Wrench 1/8 Small Flathead Screwdriver 1/4 to 1/2 Flathead Screwdriver Large Blade Flathead Screwdriver Strain-Relief Pliers Lightweight Machine Oil (Like 3-IN-ONER) Soft-face Hammer
The Basic Frame Note that the basic frame (vertical frame assembly) of the stacker is factory aligned and is not field-adjustable or field-replaceable. The basic frame includes the two vertical columns, the upper frame tie and the lower frame tie as shown below.
Figure C8. Basic Frame
C16
The Tabletop Removal 1. Remove the four screws securing the tabletop to the stacker body. There are two on either side of the tabletop. (See Figure C9) WARNING: This assembly is heavy and may cause injury should it fall while being removed from the stacker body. Be sure to provide some means of support for the tabletop when removing the screws.
Figure C9. Tabletop Removal 2. Remove the tabletop from the stacker body.
C17
Replacement 1. Reverse the above steps, being sure to provide adequate support for the tabletop while removing or replacing screws. CAUTION: The wood screws attaching the tabletop to the brackets should not be removed. In removing or reinstalling them, the holes may be stripped and the tabletop will no longer be securely held. Replace the whole table top assembly if the screws become loose or are removed.
C18
The Paddle Drive Motor Assembly
Removal 1. The paddle drive motor assembly is shielded by a cover which must first be removed to gain access to the motor. To do this, simply remove the two screws which secure the cover to the paddle drive frame. (See Figure C10)
Figure C10. Paddle Drive Motor Cover Removal 2. Using a 1.5mm Allen wrench, loosen the set screw which secures the paddle drive pulley to the motor shaft and remove the pulley. CAUTION: Do not turn motor shaft in counter-clockwise direction or you may damage the motor.
3. Disconnect the motor assemblys two-pin connector. 4. Remove the two screws which secure the motor assembly to the paddle drive frame and remove the motor. (See Figure C11)
C19
Figure C11. Paddle Drive Motor Removal
Replacement 1. To replace the paddle drive motor assembly, reverse steps 1 through 4, being sure the keyed side of the motor shaft faces the paddle drive pulleys set screw. NOTE: The gap distance between the pulley and the paddle drive frame should be set to approximately 5/32 (4mm).
2. Be sure to tighten the pulley set screw against the flat side of the motor shaft.
C20
The Upper Drive Motor Assembly
Removal 1. Remove the two screws which secure the motor cover to the upper left frame. (See Figure C12) 2. Disconnect the motor assemblys two-pin electrical connector. 3. Remove the two screws which secure the motor assembly to the upper left frame. 4. Remove the motor assembly by holding the motor and gently rotating the idler roller assembly and coupling spring off as shown.
Figure C12. Upper Drive Motor Removal
Replacement 1. Reverse the above steps. Note that the idler roller assembly and spring will go onto the motor shaft by gently rotating the idler roller in the same direction as it was rotated to remove.
C21
The Paddle Drive Belts
Removal 1. Work the belt off the paddle drive pulley as you rotate the belt in a clockwise direction. (See Figure C13)
Figure C13. Paddle Drive Belt Removal
Replacement 1. Place the belt onto the lower paddle drive pulley. 2. Work the belt over the upper paddle drive pulley flange as you rotate the belt in a clockwise direction.
C22
The Paper Shelf
Removal 1. Remove the four screws which secure the paper shelf to the base assembly. 2. Lift and remove the paper shelf. (See Figure C14)
Figure C14. Removing the Paper Shelf
Replacement 1. Reverse the steps above.
C23
The Front and Rear Paper Guides
Removal 1. Rear Paper Guide (See Figure C15) a. Remove 2 screws holding the rear paddle drive to the rear paper guide. b. Lift the rear paper guide until the bottom clears the base frame tie. c. Rotate the top of the rear paper guide in the slots in the upper frame and remove.
2a
2d
1a 2e
2b
1b
2c
Figure C15. Removing the Paper Guides
C24
2. Front Paper Guide a. Remove 2 screws holding the front paddle drive to the front paper guide. b. Remove the tray support cable from the paper tray (see Figure C23 for replacement). c. Remove 6 screws securing the paper tray and remove. d. Remove the 2 screws holding the side guide and top of the front paper guide to the frame. e. Remove the 2 screws holding the paper guide to the frame and lift the guide out. Replacement 1. Reverse the steps above.
C25
The Left and Right Vertical Frame Braces
Removal (see Figure C16) 1. Remove the 2 Phillips screws securing the left or right frame base to the frame. NOTE: If it becomes necessary to replace both frame braces, do them one at a time to keep the frame assembly square.
2. Remove 2 socket-head cap screws and washers attaching the frame braces to the base frame tie.
Replacement 1. Reverse steps 1 and 2 above.
C26
Figure C16. Removing the Vertical Frame Braces
C27
The Left and Right Upper Frames Removal 1. Remove the tabletop by removing the 4 socket-head cap screws and washers securing the tabletop brackets to the frame. DO NOT remove the 4 Phillips screws holding the tabletop to the brackets. (See Figure C17) 2. Remove the electrical cover by removing 4 Phillips screws. (See Figure C17)
Figure C17. Removing Table Top & Electrical Cover 3. Using needle-nose pliers, remove the 4 wires attached to the ON/OFF switch and the 2 wires attached to the Mode switch. Remove the wires by gently gripping the plastic connectors with the pliers and gently pulling the connectors from the switches. (See Figure C18)
C28
8
POWER ENTRY SHIELD
10
11b
4
ON/OFF SWITCH
MODE SWITCH
Figure C18. Removing Electrical Components
C29
4. Using pliers or a flat-head screwdriver, compress the plastic retaining clips holding both switches in the frame and carefully remove the switches. 5. Using needle-nose pliers, gently compress the plastic retaining clips holding the low-voltage cable in the frame and remove the connector plug from the frame. 6. Using a Phillips screw driver, remove the screw holding the plastic cover entry shield in place. Remove the power entry shield. 7. Using needle-nose pliers, remove the two wires at the top of the power entry module gently! Grip the plastic connectors and pull away from the power entry module. Be aware that the green (or green/yellow) ground wire is still attached at the bottom of the module. 8. Compress the top and bottom plastic retaining clips holding the power entry module in place and remove the module. NOTE: Use extreme caution, as the clips are breakable. Use a machinists scribe to compress the retaining clip on the bottom of the module.
9. Using a Phillips screwdriver, remove the screw securing the green and yellow ground wire running from the power entry module to the electrical housing. Note that there is a star washer under the screw clip on the wire. This must be in the same position when the ground wire is reattached. 10. Remove the two screws which attach the electrical housing to the right upper frame. 11. To remove the left upper frame, first remove the upper drive roll motor (see page C21 for removal of the upper drive motor and cover and release of the upper drive shaft), then the electrical cord, and then the spring assembly. a. To remove the connector from the electrical cord, use an AMPt Pin Pusher 458994.2 or equivalent. Push the two pins through and remove the connector plug. Using a strain relief plier, release the strain relief securing the upper drive roll electrical cord to the left upper frame and pull the cord through. Be sure to disconnect the ground wire and retain the star washer for reassembly. (See Figure C20) b. Remove the two screws which hold the spring assembly in place. Complete the removal of the spring assembly by releasing the tray support cable from the front of the paper tray. WARNING: The cable is spring loaded and may cause injury.
C30
12
12
13
12
15
Figure C19. Final Removal Steps 12. Remove the upper rear frame tie by removing the two Phillips screws holding it in place. (See Figure C19) 13. Removing the right upper frame requires the removal of the screw-mounted cable clamp which also releases the rear paddle drive cord. 14. The electrical housing is now loose and can be moved towards the back (rear) of the stacker. Note that the front paddle drive is still attached. 15. The two screws holding the left and right upper frames are now accessible. Remove the screws from the side or sides to be replaced and lift the side out. This will cause the electrical housing to hang by the front paddle drive cord.
C31
Replacement 1. Reverse steps 6 through 15, then: a. Install the OFF/ON and Mode switches in the right frame. (See Figure C18) b. Re-attach 6 wires to the switches. c. Re-attach the low-voltage cable in the right frame. d. Secure the electrical cover and table top. NOTE: Replacement of the right upper frame will require new paper length and mode labels (attached by factory) plus re-attachment of the serial number label from the old frame (attached by field service personnel). Replacement of the left upper frame will require a new voltage label (115V or 230V).
C32
The Upper Drive Bearing Removal 1. Remove the upper drive roll motor cover and motor. (See Figure C20) 2. Disengage the upper drive roll shaft per Figure C12. 3. Use a small-tip Phillips screwdriver to remove 2 self-tapping screws securing the upper drive bearing to the right upper frame. The bearing should drop off.
2 3
1
Figure C20. Removing the Upper Drive Bearing Replacement 1. Use a small-tip Phillips screwdriver to guide a self-tapping screw through the screw holes in the right upper frame. Applying pressure, turn the screw into the holes in the drive bearing. NOTE: Be sure the flat edge of the bearing is against the frame. Continue until the screw is 1/2 to 3/4 of the way in. Install the second screw in the same manner until it is tight. Now tighten the first screw.
2. Before installing the upper drive shaft, apply a single drop of 3-IN-ONE oil to the inside of the shaft bearing. 3. Reverse the steps in Figure C12 to install the shaft, motor and motor cover.
C33
The Cable Clamp Screw Mount
Removal 1. Use a pair of pliers or similar tool to hold the 4mm nut while removing the Phillips screw (see Figure C21). 2. Remove the Phillips screw and lift the cable clamp over the rear paddle drive cord.
Figure C21. Removing the Cable Clamp Screw Mount Replacement 1. Reverse steps 1 and 2 above.
C34
The Paper Shelf (with cable installation)
Removal 1. Remove the table top and the electrical cover (see Figure C17). 2. Remove the tray support cable from the front of the paper tray. Allow the cable to slowly reel into the electrical housing (see Figure C22). 3. Remove the 4 screws securing the paper tray to the left and right paper tray supports. 4. Lift the paper tray out and up to remove.
3 2 3
Figure C22. Removing the Paper Shelf
C35
Replacement 1. Reverse steps 2 and 3 in Figure C22. 2. With the table top and electrical cover off, detach the inside clip of the torsion spring from the support shaft disc (see Figure C23). 3. Pull the paper tray support cable until it completely unwinds from the tray support shaft.
3 2
6 4
5 6 (Note)
Figure C23. Reinstallation of Paper Tray Support Cable 4. Loop the tray support cable over the support shaft and feed it through the opening in the electrical housing.
C36
5. Feed the cable through the opening formed by the front paper guide and the front paddle drive pivot bracket and re-attach it to the center post of the paper tray. 6. Rewind the cable onto the support shaft, allowing for clearance of the screw holding the support disc to the moveable core. Continue rewinding until the ball slides reach the top of the electrical housing. NOTE: Make sure the side guide wings are raised to the horizontal position.
7. Adjust the height of the paper tray so there is approximately two inches between the top of the front paddle drive idler pulley assembly and the center post of the paper tray (see Figure C24).
Figure C24. Adjustment of Paper Table Height 8. Re-attach the spring assembly clip to one of the upper holes on the support disc. Adjust as necessary to maintain the proper spacing between the paper tray and the paddle drive idler assembly (see Figure C23 and Figure C24). NOTE: Center the tray support cable between the front paper guide and the paddle drive mounting bracket.
C37
9. Move the paper tray up and down to make sure the paper tray clears the paddle drive idler pulley. If there is contact, adjust the paddle drive left or right by loosening the two screws securing it to the front paper guide. After adjustments have been made, tighten the two screws. 10. Replace the electrical cover and the tabletop.
C38
Stacker Specifications
Functional Characteristics
Speed: Media Type:
Up to 24 ppm 1842 lb. continuous fanfold paper and many label stocks Width: up to 10 Lengths: 9 to 12 in half-inch increments Immediately ready on power-up 115VAC @ 60Hz (optional 220V @ 50Hz available) 10 Watts + printer consumption Temperature: Humidity: <53 dBA 5090.5_F (1032.5_C) 2080% RH
Media Size:
Warm-up: Electrical Requirements:
Operating Environment: Noise Level: Dimensions: Tabletop:
W: 20.19 (513mm) H: 36.00 (915mm) D: 31.68 (805mm) W: 20.19 (513mm) H: 36.00 (915mm) D: 18.50 (470mm) 55 lbs. (24.97 kg) CSA, NRTL/C, TUV Warranty period of one year
Stand-alone:
Weight: Certifications: Warranty:
C39
Test Data Media tested: medium weight bond (1824 lb.) and heavy weight bond (>24 lb. and <40 lb.) Under nominal temperature and humidity 1 mis-stack in 6000 pages 1 mis-fold in 3000 pages Under conditions of extreme temperature and humidity 1 mis-stack in 4000 pages 1 mis-fold in 2000 pages NOTE: A mis-stack is defined as any media movement in the stacker which results in a fatal printer fault (printer halts), causes the media to overflow the stacker, or requires operator intervention. A mis-fold is defined as abnormal media handling in the stacker which allows printing and stacking to continue and does not result in paper jams, fatal printer faults, or stacker overflow. Extensive testing has proven that the stacker performs reliably when stacking 20 lb. paper with a 1/32 tie, eight cuts per inch and 20 lb. microperf paper. Products which may result in stacker mis-stacks or mis-folds are: S S S S S 16 lb. (or lighter) paper Microperf paper of less than 20 lb. weight Light paper at high humidity Paper with perforations having more than 8 cuts per inch Label stock with a weak backing and several labels per sheet.
Auto Stacker Interface Specifications S 324VDC is required to operate the solid-state relay. S At 5VDC, the relay draws <4mA S The potential across these wires should exist when paper begins to move (as evidenced by the PMOVE signal on the engine/controller interface) and continues for about 0.5 seconds after the PMOVE signal is absent. S The connector on the Stacker is a Molex Mini-Fit Jr. Receptacle, (Molex P/N 39012020). S The matching plug on the OEMs connecting wire is the Molex Mini Fit Jr. Plug (Molex P/N 39012021). S Maximum cable length from the printer to the stacker is undefined at this time. S No shield ground is provided at the stacker end. This prevents undesirable ground loops.
C40
Printing This appendix outlines the principles of laser printing technology and gives a step-by-step explanation of the process. The printer performs printing operations in seven steps. The following steps are described in the subsequent paragraphs: S Charging the OPC drum S Exposing the OPC drum with the LSU to form a latent image S Developing the print image by attracting toner onto the OPC drum S Transferring the toner image from the OPC drum onto the media S Cleaning the OPC drum of the unused toner S Erasing the static charge from the OPC drum S Fusing the toner image to the media
D1
Charging the OPC Drum The main component of the printing system is the OPC (organic photoconductor) drum. It is a cylinder with special properties. The material of the OPC is an insulator when in the dark and is conductive when exposed to light. Before beginning the process, the OPC drum must be electrically charged. Figure D1 shows the organization of the OPC drum charger. A single tungsten wire is centered in a metal channel over the OPC drum. This channel has a wire grid between the lower open end of the channel and the material of the drum. The air around the wire is ionized by the high negative potential, approximately 5000 volts, of the wire. The grid of the channel is maintained at a voltage less negative than the tungsten wire, approximately 680 volts. This voltage differential controls the ions flying toward and past the grid and onto the OPC drum. These ions set up a negative potential of approximately 700 volts on the surface of the OPC drum as it rotates under the metal channel.
Metal Channel Tungsten Wire (Charge Corona) Grid OPC Drum Rotation
High Negative Potential Less Negative Potential
OPC Drum Rotation
Figure D1. Charging the OPC Drum
D2
Exposing the OPC Drum (Forming the Latent Image) Inside the lid of the printer is a modulated semiconductor laser. The beam of the laser shines on a rotating polygonal mirror which causes the beam to scan across the OPC drum. The beam discharges the negative potential of the drum in the pattern of the desire image. This gives the image portion of the OPC a less negative potential than the rest of the OPC, approximately 100 volts, while the unexposed portion of the OPC maintains approximately 700 volts. The electrical pattern formed by this process is called the latent image. This process is illustrated in Figure D2.
Light
Dark

OPC Material OPC Drum Surface

Conductive Base Material
Low Negative Voltage
High Negative Voltage
Nonexposed Portion (High Negative Voltage)
Exposed Portion (Low Negative Voltage)
Figure D2. Exposing the OPC Drum
D3
Developing the Print Image The OPC drum, with its latent image, rolls past the sleeve and magnet roller, which is part of the developer unit. The powdered toner is magnetized, which keeps it lightly attracted to the sleeve over the magnet roller. The sleeve is charged to approximately 500 volts. As the image on the OPC drum passes the developer unit, the negatively charge toner is attracted to the exposed areas of the drum because of the voltage difference (500 to 100 volts) as shown in Figure D3. On nonexposed areas of the drum, the reverse is true. The negatively charged toner is forced away by the higher negative charge on the drum (500 to 700 volts). The toner image on the drum is called the developed image.
Doctor Blade
Toner and Carrier
S N S
S N
Sleeve
S
Magnetic Roller
OPC Drum
Figure D3. Developing the Print Image
D4
Transferring the Toner to the Print Media The print medium, normally paper or label stock, passes between the OPC Drum and a second metal channel containing a tungsten wire charged to approximately +4200 volts. This charge is transferred to the media, as shown in Figure D4. As the media passes the rotating OPC drum, the negatively charged toner is transferred to the positively charged paper in the pattern of the developed image.
OPC Drum Rotation
Toner
+ + ++ ++ ++++ +
Print Medium
Tungsten Wire (Transfer Corona) at +4200 Volts
Metal Channel
Figure D4. Transferring the Toner to the Media
D5
Cleaning the OPC Drum Any toner remaining on the OPC drum is wiped from the drum with a doctor blade. The toner removed from the OPC drum is dropped into the screw assembly, which moves the used toner laterally to the waste toner container, as shown in Figure D5.
Doctor Blade OPC Drum Rotation Toner
Toner Removal Screw
Figure D5. Cleaning the OPC Drum
D6
Erasing the Static Charge An array of LEDs shines on the OPC drum before it moves again past the charger assembly, as shown in Figure D6. The light causes the drum to conduct, allowing the charge to drain to ground before the next cycle begins.
Charger Unit Metal Channel
Tungsten Wire (Charge Corona) LED Assembly
OPC Drum Rotation
Light Media
Transfer Unit
Figure D6. Erasing the Static Charge
D7
Fusing the Toner Image to the Media The media now has the toner image. The media moves between two rollers, a heat roller and a pressure roller, as shown in Figure D7. Together, the heat roller melts the toner, while the pressure roller presses the image into the media. The printing cycle is now complete, and the media exits the rear of the printer.
Fuser (Heat) Roller
Media Toner Side
Pressure Roller
Figure D7. Fusing the Toner Image to the Media
D8
PRINTRONIX
17500 CARTWRIGHT ROAD P.O. BOX 19559 IRVINE, CA. 92623-9559 PHONE: 714/863-1900 FAX: 714/660-8682 TECHNICAL SUPPORT: 714/221-2686 NEDERLAND BV P.O. BOX 163, NIEUWEWEG 283 NL-6600 AD WIJCHEN THE NETHERLANDS PHONE: (31) 24 6489489 FAX: (31) 24 6489499
42 CHANGI SOUTH STREET 1 CHANGI SOUTH INDUSTRIAL ESTATE SINGAPORE 486763 PHONE: (65) 542-0110 FAX: (65) 543-0220
PRINTRONIX
PRINTRONIX A.G.
http://www.printronix.com
VISIT
OUR WEBSITE AT:
704792001C

L1024 24-Ppm Continuous-Form Laser Printer

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L1024 Continuous Form Laser Printer

L1024 Continuous Form Laser Printer

Printronix is a registered trademark of Printronix, Inc.

COPYRIGHT 1996, 1997 PRINTRONIX, INC.

Table of Contents Chapter 1 Introduction

Chapter 3 OPC Drum Unit Subsystem

Chapter 4 Developer Subsystem

Chapter 5 Transfer Subsystem

Chapter 6 Paper Feed Subsystem

629 630 631 631 632 632 632

Chapter 7 Fuser Subsystem

Chapter 8 Power Supplies

Chapter 9 Controllers and Floppy Disk Drives

Chapter 10 Control Panel

Chapter 11 Laser Scanning Unit (LSU) Subystem

Chapter 12 Covers, Frame, and Backplane Board

Chapter 13 Troubleshooting Guide

1341 1341 1341 1341 1342

Appendix D Principles of Operation

CLAMSHELL LSU (LASER SCANNING UNIT)

HIGH VOLTAGE SUPPLY

LEFT FRAME TRACTOR TRANSFER OPC DEVELOPER

FUSER ROLLER ASSEMBLY FUSER BASE

STEPPER MOTOR & CONTROL BOARD HOUSING LOW VOLTAGE SUPPLY

BASE PAN TENSION ROLLER

DATA CONTROLLER BOARD BOTTOM COVER

Figure 11. Major Subassemblies.

Cleaning Area Tension Roller

Cleaning Tool Wet Wipe Tissue

Figure 12. Cleaning the Tension Roller

(Continued on next page)

Cleaning Tool Refer to the Setup Guide.

Method Refer to the Setup Guide.

Wet Wipe Tissue

LSU Cover Glass

Cotton Swab and Rubbing Alcohol

Clamshell and Subassemblies

030129308 202294551 202118551 202575001

Latch Assembly Detail 11 1 14 1 33 1 34 1 8 2 12 1

Top Cover, Latch, and LED Assemblies

2.1.2 Catch Release Assembly

2.1.3 Left and Right Catch Assemblies

2.1.4 Miscellaneous Components

1 Ref Catch Release Assembly

9 1 7 Ref Left Catch Assembly 11 2 2 Ref

12 Ref Right Catch Assembly

19 2 8 1 16 1 14 2 15 1 13 1 11 2 18 1 Left Hinge Assembly Right Hinge Assembly

2.1.5 Left and Right Hinge Assemblies

2.2 Clamshell Overview 2.2.1 Mechanical

Block Diagram 21. Top Cover Electrical

2.3 Top Cover Assembly 2.3.1 Removal and Disassembly

Latch Removal Detail

Figure 21. Top Cover Disassembly

1. Lift Front Cover, then disengage rear Locking Tabs.

2. Depress tab to remove Hinge Cover.

Detail 21. Removing Top Cover and Hinge Covers

2.3.2 Reassembly and Replacement

2.4 Latch Assembly 2.4.1 Removal and Disassembly

2.4.2 Reassembly and Replacement

CORRECT LATCH RELEASE POSITION

Detail 22. Correct Latch Release Position

2.5 Catch Release Assembly 2.5.1 Removal and Disassembly